CAT Dragline Marion 8200 DRAGLINE MAINTENANCE AND OPERATION Manual

EM029421-0 (en-us)

EM029421-0 (en-us)

EM029421-0 (en-us)

8200 .DRAGLINE MAINTENANCE AND OPERATION MANUAL 2101

MARION POWER SHOVEL DIVISION-DRESSER INDUSTRIES, INC. USA . . Printed in USA

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8200 WALKING DRAGLINE WARD LEONARD- STATIC CONTROL-INDEPENDENT PROPEL

SPECIFICATION 8200-52A Boom length (Centerline) ............................................ 350'-0" A- Boom Angle (Approx.) ........................................... 35-1/4° B - Dump Radius .................................................. 312'-0" C - Dump Height .................................................. 155'-0" D - Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145'-0" E -Tub Nominal Outside Diameter ..................................... 68'-0" Rail Circle Mean Diameter ......................................... 50'-0" Main Swing Gear Pitch Diameter ..................................... 39'-9" F -Width of Shoe ................................................... 13'-0" G - length of Shoe .................................................. 70'-0" H -Width over Both Shoes ............................................ 96'-0" length of Step (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7'-0" J - Rear End Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77'-0" K - length of Rotating Frame ................. : ....................... 92'-6" L - Rear End Clearance Radius ......................................... 71 '-0" M- Clearance Under Rotating Frame ..................................... 8'-0" N - Center Rotation to Boom Foot ...................................... 21 '-6" P - Ground to Boom Foot . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15'-1" Working Weight, Lbs. . ......................................... 8,754,800 Ballast, Lbs. . ................................................ 1,250,000 Maximum Allowable Load, Lbs ..................................... 380,000

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This manual is divided into sections covering various serviceable components and systems of the Model 8200 dragline. These sections are organized by thumb index tabs shown below and right-black ink tab marks.

SECTION 1 - INTRODUCTION

SECTION 2- OPERATION

SECTION 3 - LUBRICATION

SECTION 4- MECHANICAL ADJUSTMENTS

SECTION 5- ELECTRICAL MAINTENANCE

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SECTION 6- COMPRESSED AIR SYSTEMS

SECTION 7- ENGINEERING DATA

SECTION 8- INSPECTION SCHEDULE

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SECTION 1 INTRODUCTION INDEX Page General Information ........................................ 1-1 Safety Precautions ......................................... 1-2 Preventive Maintenance ..................................... 1-6 Warranty ................................................ 1-8 Training .................................................. 1-9

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SECTION 1 INTRODUCTION GENERAL INFORMATION

This manual is designed to assist the owner in the operation and preventive maintenance of this machine. Following easy to understand step-by-step procedures, maintenance personnel can perform these tasks in a safe manner. When a systematic and thorough maintenance/ service procedure (a responsibility of the maintenance superintendent) is used for this machine, minimum unplanned downtime and reliable operation will result.

THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with item/part numbers for THIS SPECIFIC MACHINE. Order parts in exact quantity. Parts ordered by mistake and returned, are subject to a rehandling charge. RIGHTand LEFT HAND PARTS on the upper frame correspond to the operator's hands at the controls; as seated when operating the machine.

Please state the correct machine SERIAL NUMBER (located on a plate in the operator's cab) when corresponding or contacting factory service or parts departments. Records on each machine are filed by serial number and when given this number, your machine's specific design and original equipment is accessed quickly by the Marion parts representative.

Periodic additions or revisions may be made to this manual. These will be mailed direct to you from the factory. Should you require additional information or factory service assistance contact your regional service representative or Service Department Marion Power Shovel Division Dresser Industries, Inc. 617 West Center Street P.O. Box 505 Marion, OH 43302

or: Telephone 614/383-5211 Telex 24-5307 TWX 810/487-2772 Telecopier 614/383-5211

It is Marion Power Shovel Division policy to improve its products whenever possible and practical to do so. Marion reserves the right to make changes or add improvements at any time without incurring any obligation to install such changes on machines sold previously.

Due to this continuous program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve machines.

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SAFETY PRECAUTIONS

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This safety alert symbol is used here and throughout this manual to call your attention to instructions concerning your personal safety. Carefully read and follow these instructions and observe all safety and danger, and caution graphics mounted on various areas of the machine.

Be certain anyone servicing this machine is aware of these SAFETY PRECAUTIONS. In the event you question your ability to safely perform any of the enclosed maintenance and operational procedures contact your regional Marion service representative or the factory.

The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.

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DANGER:

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

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

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

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DANGER:

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

Operating, maintaining or servicing this machine can be dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert and has the necessary skill and information, proper tools and equipment, and all methods are safe and correct.

Factory service representatives and specialists are available to provide additional information or technical assistance.

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SAFETY PRECAUTIONS- continued The operator must be alert, physically fit, and free from the influence of alcohol, drugs, or medications that might effect his eyesight, hearing or reactions.

Safety must always be the operator's most important concern. He must refuse to operate when he knows it is unsafe, and consu It his supervisor when safety is in doubt.

The owner and/or operator must replace any and all safety and warning product graphics if they are defaced or removed from the machine.

Before doing any work on the machine, lock out or remove electric power supply from the machine and tag it so personnel are aware that someone is working on the machine.

Keep hands, feet, clothing away from rotating parts.

Before walking machine, place trail cable in a safe position.

Think before you act. Carelessness is one luxury the serviceman cannot afford.

Do not wear rings, wrist watches or loose fitting clothing. They could catch on moving parts causing serious injury. Never adjust and/or service a machine in bare feet, sandals or sneakers. Never work on rotating or moving machinery.

Always wear safety glasses when using a hammer, chisel or other tools that may cause chips to fly.

Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact, remove sealant or solvent promptly by washing with soap and water.

Always use a safety bar to block air or hydraulic operated cylinders. Never rely on the machine air or hydraulic systems to hold when working on machines. An air or hydraulic line or cylinder could fail or someone could accidently strike the control levers causing the equipment to fall.

Equipment must be level on ground at all times during machine servicing and periods of idleness.

Cranes and hoists must be of sufficient capacity to lift the heavier components (gear cases, dipper/bucket, boom, etc.) and have an ample safety margin.

Be sure heavy items are properly supported from cranes or hoists before removing supporting members from machine.

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SAFETY PRECAUTIONS- continued Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times.

Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they could fail.

Use safety catch on all hoist hooks. Do not take a chance, the load could slip off of the hook.

If a heavy item begins to fall, let it fall, don't try to catch it.

When disassembling machines, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.

Keep work area organized and clean. Wipe up oil or spills of any kind. Keep tools and parts off of the ground. Eliminate the possibility of a fall which could result in a serious injury.

Floors, walkways and stairways must be clean and dry. After draining operations be sure all spillage is cleaned up. Electrical cords and wet metal floors make a dangerous combination.

Check all wire ropes for telltale signs of early wear or failure. Look for and secure any loose bolts or locking devices.

Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless qualified. Check limit switches for proper operation.

When using an acetylene torch, always wear welding goggles and gloves. Keep a "charged" fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart. Do not weld or heat areas near transformers or electrical cabinets and utilize proper shielding around lubrication lines.

Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Then, be sure to wear safety glasses.

Be careful when using compressed air to dry parts. Use approved air blow guns, do not exceed 207 kPa (30 psi), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.

Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

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SAFETY PRECAUTIONS- continued After servicing, be sure all tools, parts or servicing equipment are removed from the machine.

Protective eye goggles should be worn at all times when working on the air conditioning system. Work on the air conditioning system only in a well ventilated area.

Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.

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

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PREVENTIVE MAINTENANCE

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Machine downtime is costly to owners in lost production. Preventive maintenance is the task of identifying, replacing or repairing machine components before they fail so that downtime is minimized.

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CAUTION:

Do not perfonn inspection activities while machine is in operation.

Due to variations in operational wear rates of machine components and machine application conditions, component life cycles are different. A scheduled program of machine inspection with accurate record keeping can identify machine component and their rates of wear.

A continuous careful inspection routine can spot unusual conditions or fatiguing components before a failure occurs. Maintenance, repair and component replacement schedules should conform to scheduled machine shutdowns. If during daily, weekly or monthly inspection routines any part shows wear or distortion beyond expected normal patterns replace them with genuine Marion parts at the next scheduled maintenance interval. The cost of parts is small when compared to unscheduled breakdowns with their resulting lost manhours and machine production.

Machines which operate 24 hours, 7 days per week should have a scheduled 8-hour preventive maintenance period each 7-day period. See Section 8 for recommended inspection schedules.

Preventive maintenance inspection procedures listed below are suggested as an example of specific typical inspection activities. Each owner should establish his own preventive maintenance inspection schedule based on machine application conditions and production cycle.

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CAUTION:

Maintenance and operating personnel should be aware of mechanical and electrical hazards inherent in servicing this machine.

INSPECTION CHECKLIST Check condition of rope sheave grooves and bearings Test all hold down bolts with impact wrenches Check rope guides and bails for wear Inspect all rope for broken wire or loss in diameter Check auto-lube system for loose or damaged fittings and injector condition Inspect dipper/bucket for cracks

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DANGER:

Remove electrical power from machine whenever inspection of center journal, collector rings, rails or roller circle is performed. Use extreme care in removing guards and protective devices.

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PREVENTIVE MAINTENANCE- continued INSPECTION CHECKLIST Check condition of roller circle, rails, and gearing Check main swing gear hold down bolts andre-torque to specifications Test all hold down bolts on upper frame components such as swing gear case, electric motor mounts, machinery pedestals and air compressors Examine all brakes, clutches and their linings for excessive wear Check center journal---secure all guards and protection devices removed

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DANGER:

REMOVE ELECTRICAL POWER FROM MACHINE BEFORE PERFORMING ANY OF THE FOLLOWING INSPECTIONS:

Inspect electrical cabinets; any discolored wires or components indicate overheating conditions have occured.

Look for moisture, fungus or mildew in electrical cabinets. If found clean with approved solvents only, or compressed air.

Check all electrical cabinets for messy or torn fasteners, cable armor or grommets, loose insulation Inspect electrical motors for discolored commutators or worn brushes.

These inspection points are representative of typical preventive maintenance routines. Use Section 8 as a detailed guide for all areas of machine inspection and suggested scheduled periods.

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*STANDARD WARRANTY

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Marion Power Shovel Division, Dresser Industries, Inc. ("Marion") warrants that its products, when shipped, for a period of six (6) months from the date of delivery, F.O.B. point of shipment, will meet applicable, agreed specifications, if any with respect thereto, and will be free from defects in material and workmanship, provided that the Marion products sold are properly stored, assembled, used and maintained. Products not manufactured by Marion shall be subject only to such warranty as may be made by the manufacturer thereof. All claims under this warranty must be made in writing immediately upon discovery. THE FOREGOING IS EXPRESSlY IN liEU OF All OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLIED AND STATUTORY, INClUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS.

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Should any failure of the Marion products to conform to this warranty appear within the limited time period set forth above, Marion shall, upon Buyer's submission of a claim as provided above, either 1) repair or replace, F.O.B. point of shipment, any nonconforming part or parts of Marion's products which have been returned to it for examination, transportation prepaid, or otherwise examined by Marion, and which examination discloses the nonconformity to Marion's satisfaction; or 2) refund an equitable portion of the purchase price.

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THE FOREGOING IS MARION'S ONlY OBLIGATION AND BUYER'S EXClUSIVE REMEDY FOR BREACH OF WARRANTY AND, EXCEPT FOR GROSS NEGLIGENCE OR WillFUl MISCONDUCT, THE FOREGOING IS BUYER'S EXCLUSIVE REMEDY AGAINST MARION FOR All ClAIMS ARISING WITH RESPECT TO MARION PRODUCTS OR RElATING THERETO, WHETHER SUCH ClAIMS ARE BASED ON BREACH OF CONTRACT, TORT (INClUDING NEGLIGENCE AND STRICT liABiliTY) OR OTHER THEORIES. BUYER'S FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICAllY WAIVE All ClAIMS FOR DAMAGES OR OTHER RELIEF, INCLUDING, BUT NOT LIMITED TO, ClAIMS BASED ON lATENT DEFECTS.

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IN NO EVENT (INCLUDING, BUT NOT LIMITED TO, AVOIDANCE OF THE ABOVE LIMITED WARRANTIES AND REMEDIES) SHAll BUYER BE ENTITLED TO ANY INDIRECT, SPECIAL, INCIDENTIAl OR CONSEQUENTIAl DAMAGES, WHETHER ARISING FROM lATE PERFORMANCE OR A FAilURE TO PERFORM, DEFICIENCIES OR NEGLIGENCE IN THE DESIGN, MANUFACTURE, SAlE DELIVERY OR ASSEMBLY OF MARION PRODUCTS OR FAILURE OF MARION PRODUCTS OR FROM ANY CAUSE WHATSOEVER AND WHETHER BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABillTV) OR OTHER THEORIES. ANY ACTiON BY BUYER ARISING WITH RESPECT TO MARION PRODUCTS OR RELATING THERETO MUST BE COMMENCED WITH ONE (1) YEAR AFTER THE CAUSE OF ACTION ACCRUES OR IT SHALl BE BARRED.

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Marion reserves the right to improve or change the design of its products and specifications thereof and Marion shall incur no liability thereby or any obligations to install such improvements on products previously sold.

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*The above warranty relates to spare/repair parts for the Marion equipment referenced in this document.

For specifics on the machine warranty, reference should be made to the purchase contract or Marion Power Shovel Division, Dresser Industries, Inc. may be contacted directly. Please identify machine serial number.

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TRAINING

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Qualified maintenance personnel using a scheduled maintenance program are the best way to minimize machine downtime and maximize productivity of equipment.

Marion offers factory and mine site maintenance seminars and special familiarization programs for mechanics, oilers, electricians and operators on a fee basis.

These programs are presented by qualified factory specialists and service technicians. Special customized training programs can also be developed to meet specific mine requirements.

Objectives of training and training materials are to provide the means for developing and maintaining on-site service repair capability. The Marion training programs use field proven concepts where your employees see, hear and participate in "hands on" practice of service repair operations.

For further information about Marion service training capabilities and programs contact: Training Supervisor Marion Power Shovel Division P.O. Box 505 Marion, Ohio 43302

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SECTION 2 OPERATION INDEX Page Operator's Cab and Anteroom ................................ 2-1 Primary Controls .......................................... 2-2 Comment About Primary Controls ............................. 2-4 Plugging the Motion ........................................ 2-4 Control Panels ............................................ 2-5 Annunciator Readout Panel .................................. 2-8 Overtemperature Alarm Panel ............................... 2-11 Controls in Machinery House ....... ; ........................ 2-12 Visual Inspection ......................................... 2-14 Genera I Check List ........................................ 2-14 Tub Check List ........................................... 2-14 House Check List ......................................... 2-14 Front End Check List ...................................... 2-15 Typical Start-up .......................................... 2-15 Drag Mode .............................................. 2-17 Typical Digging Cycle ...................................... 2-18 Propel Control ........................................... 2-19 Ground Preparation ....................................... 2-20

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Section 2- Operation (cont.)

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Ramping ................................................ 2-21 Walking Machinery ........................................ 2-22 Typical Partial Shutdown ................................... 2-23 Completely Shutdown ..................................... 2-23

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SECTION 2 OPERATION

OPERATOR'S CAB AND ANTEROOM extends out from the front corner of rotating frame, which gives operator clear vision of pit, boom point and front end.

The cab contains the primary controls and indicators for operating the machine. The anteroom contains crew lockers, tool box/bench, desk with storage space for this manual and a bulletin board.

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The interior walls and ceiling of both rooms are covered with durable vinyl and can be cleaned with a damp cloth and soap. The floor is covered with seamless material for sound deadening and easy maintenance. Insulation is installed in walls, ceiling and cab base.

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The cab forced air combination heater-defrosting and air conditioning unit is located in the cab base. The registers are in the floor around operator, with return registers mounted in rear wall of cab. The controls are also mounted on rear wall.

Before operating the machine, sit in the "driver's seat" (facing boom) and adjust the seat to you. Remember that you are going to be sitting for long periods of time so get comfortable.

Adjust the height, so that the swing (foot) pedals can be depressed with- out reaching, by turning the wheel in ~ the appropriate direction. /

After adjustment is made sit in the seat, look around and familiarize yourself with the location of the operating controls.

NOTE: RIGHT and LEFT HAND direction correspond to the operator's hands at the controls as he faces the boom.

PRIMARY CONTROLS are the hoist and drag hand lever controllers and the swing pedals at your feet.

The hoist controller (at your right hand) is an electrical, lever activated, switch mounted to the hoist control stand. The switch controls hoist machinery speed to raise or lower the bucket. Pulling lever back raises, forward movement lowers the bucket. Stop bucket motion by plugging the controls, that is moving the lever to or past neutral to the position opposing bucket motion. See PLUGGING MOTION. The thumb latch controls the electric horns.

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Hoist Stand

The drag or propel controller lever (at your left hand) works like the hoist lever except it operates the drag and propel machinery depending on which mode the machine is in. Moving lever rearward, drag mode, causes bucket to be pulled toward machine. Moving lever forward causes the drag rope to pay out, thus allowing bucket to dump or return to dig position. The drag motion is stopped by plugging the controls. The thumb latch, when depressed, applies reduced hoisting power to hoist drum. This is used to remove hoist rope slack and hold rigging off bucket when dragging.

When in propel mode (see OPERATING THE WALKING MECHANISM) full forward position of the lever controls the propel motors, which in turn starts the walking step.

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The swing pedals, centered on floor in front of seat, control the machine rotation. Pressing right pedal, machine swings right. Left pedal causes a left swing or rotation. The swing motion is stopped also by plugging the controls, that is, depressing opposite swing pedal to

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Left Swing

slow or stop motions. The pedals are linked together so that only one pedal can be pressed.

When no pressure is applied, the pedals will self-neutralize in the neutral position.

COMMENT ABOUT PRIMARY CONTROLS -The hoist and drag controller is a SPEED REGULATOR. Practically full torque or line pull is obtained with the slightest handle movement. Move lever only far enough to obtain desired speed. Do not move lever(s) too far, then back off. Use smooth movements, lever jockeying is not required and only results in overheating the motors.

The swing pedals are a TORQUE REGULATOR. The swing torque applied to machine increases as the pedal is pushed farther down and thus the acceleration rate is increased. This means full swing speed is obtainable at any pedal position.

PLUGGING THE MOTION means reversing the generator field to act as a braking force and stop motion.

In normal operation, stop or retard the motion of D.C. drive motors by moving the control lever (or pedal) in the opposite direction. This reverses the current in the generator field.

This reversing of field acts as a braking force, retarding or stopping the motion. At the same time the rotation reaches zero, you must move the controller lever (or pedal) to the neutral position.

Plugging the motion rapidly dissipates the energy of heavy rotating parts by regenerating

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back into the power source, thus preventing heat created by mechanical friction brakes.

If hoist or drag controllers are returned to neutral with machine in motion, the control automatically plugs that motion to slow it dowh and finally come to rest.

CONTROL PANELS on top of each controller stand contains push buttons, selector switches and indicator lights; all clearly marked.

Hoist Stand

The panel located on top of hoist stand (right hand) contains five lights, three selector switches and three push buttons. They are: 1. Propel Brake. This red light will come on when the propel brakes are set.

2.

Drag-Propel Brake. This switch will either set or release the drag or propel brakes depending on which mode the machine is in.

3.

Drag Brake. This red light, when lit, indicates the drag brakes are set.

4. Swing Brake. Moving this switch to the left sets the swing brakes and right movement releases them. The red light will come on when the brakes are set.

5.

Hoist Brakes. This switch either releases or sets the hoist brakes. The red light, when lit, indicates the hoist brakes are in the set position.

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NOTE: The brakes are holding brakes ONLY and are NOT intended to stop or retard the rotating of the motor armature and/or machine motion EXCEPT in emergency. See PLUGGING THE MOTION. 6.

M-G Set Stop. When pressed, the M-G sets will stop.

7.

Excitation On. This green indicating light indicates that hoist, drag and swing controllers are energized.

8.

Emergency Stop. When this red mushroom type push button is pressed ALL brakes will set and ALL controls will de-energize.

9.

Excitation Start. This push button energizes the hoist, drag, swing controllers and the solenoid circuits.

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The air pressure gauge is located on right side of this panel. The operator should monitor this gauge often. The gauge should read 95 psi minimum while machine is in operation.

When pressure drops below 95 psi, shutdown the machine and investigate the problem.

Two pairs of test jacks are located on right side of the stand, near the air gauge. They are wired into the Power Control Room and are used to monitor circuits for boom lowering, etc.

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Drag Stand

The panel located on top drag stand (left hand) contains two indicators, three lights, five push buttons and two selector switches. They are:

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10.

Ground Check Pushbutton. Pushing this will open the trail cable ground monitor system thus tripping the pit substation circuit breaker.

11. Windshield Wiper. This on-off switch controls the electric motor, with gear reducer, mounted on outside of sliding front window at upper left hand corner. Maintain wiper sweep by adjusting the rod between the gear reducer and wiper pivot. The wiper pressure on the glass is adjusted by the nut on the spring rod located at top of wiper arm on outside of window.

12. Propel Error Bypass. This push button overrides the synchronizing shutdown relay. If both walking mechanisms are not synchronized the relay drops out, deactivating the propel machinery. The override allows shoes to be realigned. (See Operating the Walking Mechanism.)

13. Cab Light. On-off switch controls the cab interior lights.

14.

Shoe Park. Use this push button to stop walking shoes in the park position. (See Operating the Walking Mechanism.)

15. Clear to Swing. position.

16.

When this green light is lit the walking shoes are in the park or up

Drag Mode. Green light indicates that the machine is in the drag mode.

17. Propel Mode.

When lit this amber light indicates that machine is in propel mode.

18.

Drag Transfer. Pressing this button puts machine in drag mode.

19.

Propel Transfer. This push button puts the machine in the propel mode.

20 & 21. Left and Right Hand Shoe Position Indicators. These two 360 degree solid state meters indicate the position of the two walking cams by illuminating the dial as the cams travel in their 360 degree circle.

The telephone located on left side of drag stand links the operator with other phones located at various spots on or about the machine.

Two warning bells are located on front of the drag stand. One is the rope limit bell (single stroke) that is activated by the rope limit control system. Thus bell will sound when a first stage hoist, drag or tightline limit is reached. The other bell is for the phone and ground signal.

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The ANNUNCIATOR READOUT PANEL, located at right of the operator's seat, consists of warning lights, push buttons and L.E.D. display, all wired into various mechanical or electrical functions.

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When a light comes on, an audible alarm will sound to alert the operator. The light identifies where the malfunction or maladjustment is located. The silence button (38) in middle of panel will stop the alarm but lamp will remain on until condition causing alarm has been corrected.

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ANNUNCIATOR PANEL

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The items on the annunciator panel are as follows: 1. Main Transformer Alarm Light indicates that the slow gas, oi I level or oil temperature relay on the 10,000 KVA transformer has operated.

2. Over-Under Frequency Light indicates a fault or malfunction in incoming power supply.

3. AC Undervoltage Light indicates that incoming voltage is dropping below 85 percent of its nominal value.

4.

M-G Overspeed Light indicates that an M-G set is overspeeding. This condition will stop the affected M-G set and shut down the machine.

5. 480 Volt Ground Light indicates that a ground has occurred on one of the phases of the auxiliary transformer.

6.

DC Motor Field Loss Light indicates the loss of DC motor field excitation.

7.

DC Loop Unbalance Light indicates that a loop unbalance has occurred. The motion in which unbalance occurs will be shut down.

8.

DC Loop Ground Light indicates a ground in a DC motor armature loop. Latching relays in the power control room will identify which loop has grounded. This is a warning light only, with no machine shutdown.

9.

DC Motor Blower Loss Light indicates when any DC motor blower loses power and stops.

10. DC Motor Overtemperature Light indicates overheating in any of the DC motors. This is a warning only, there is no shutdown.

11. Synchronous Motor Protection Light indicates that the pullout or field current relay, on one of the synchronous motors, has operated.

12. Propel Error Light indicates that walking shoes are out of sync.

13.

Rope Limit Light indicates that bucket has either entered a final hoist or drag limit position or is in a final tightline limit.

14.

Limit System Fault Light indicates that the electronic rope limit control system selfdiagnostic feature has detected a malfunction in one of the components of this control.

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15.

Brake Set Light indicates that one of the motion brakes is not fully released.

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16., 17. Propel Bushing Temperature- left and right side lights indicate that one of the overtemperature devices, monitoring the propel bushing, has operated.

18.

Drum Bearing Temperature Alarm Panel Light indicates operation of one or more temperature warning points on the alarm panel located on the cab wall behind the operator.

19.

Auto Lube Light indicates when one or more of the automatic lube systems has not completed a cycle within the allotted time interval.

20.

Low Air Pressure Light indicates when system pressure falls below 95 psi.

21. Swing Oil Flow Light indicates motor or pump failure, blocked filter, etc. in one or more rotating gear case lubricating systems.

22. Structure Pressure Loss Light indicates loss of air pressure due to a crack or break in the boom apex piping or tri-structure. This is a warning light only, with no shutdown.

23.

Swing Pinion Loss Light indicates that one of the detectors, monitoring the swing pinions, has detected a downward movement of a pinion.

24.

Slack Rope Limit Light indicates that the hoisr or drag slack rope limit switch has operated.

25.

Fire System Pressure Light indicates that the pressure switch, which monitors the water fire system air supply, has detected a drop in air pressure.

26. thru 30. Spares available for Customer use.

31.

Left Shoe Pushbutton. Pressing this button will display the left shoe position in degrees of rotation from top dead center (TDC).

32.

Right Shoe Pushbutton. Pressing this button will display the right shoe position in degrees of rotation from top dead center (TDC).

33.

Shoe Error Pushbutton. Displays left/right shoe position error in degrees.

34.

Hoist Drum Pushbutton. Displays distance of bucket from boom point in feet.

35.

Drag Drum Pushbutton. Displays distance of bucket from fairlead in feet.

( 2-10

EM029421-0 (en-us)

36.

Limit Bypass Pushbutton. tightline limit.

This button is used to back out of a final hoist, drag or

37.

Lamp Test Pushbutton. Operate to check all warning lights on panel. Replace burned out lamps prior to operating machine.

38. Alarm Silence Pushbutton. Operate to shut off audible alarm. Warning light will remain on until malfunction has been corrected.

39., 40. Hoist and Drag Zero Set Pushbuttons are used to calibrate the rope limit control system. See Marion Protection System operating manual for details.

41. L.E.D. three digit display for Items 31 thru 35.

OVERTEMPERATURE ALARM PANEL MASTER MODULE Drag Drum Shaft Left Side

Hoist Drum Shaft Left Side

Drag Drum Shaft Right Side

Hoist Drum Shaft Right Side

OVERTEMPERATURE ALARM PANEL- This panel is mounted on the rear wall of the operator's cab. It consists of two dual input modules and a single master module used to readout actual temperatures being monitored and to set the temperature alarm trip point of each of the four points.

Temperatures are monitored in each hoist and drag drum shaft bearing. The recommended initial temperature alarm set point is 80 degrees C. The final set point may vary slightly, depending upon operating conditions and climate. Any alarm from this panel requires immediate investigation to avoid subsequent damage.

2-11

EM029421-0 (en-us)

CONTROLS IN MACHINERY HOUSE, located on outside of power control room, are used by the operator for start-up and shutdown.

(

STARTING AND METERING PANEL

A.

A.C. Watt Meter. (Incoming Power).

B.

Time Meter. Registers total operating time.

C.

VarMeter. (Incoming Power).

D.

D.C. Voltmeter. Measures house exciter (D.C. control) voltage.

( 2-12

EM029421-0 (en-us)

E.

A. C. Ammeter. Shows the current in high voltage lines, thru the auxiliary transformer and the M-G set motors.

F.

A.C. Voltmeter provides a visual reference of incoming voltage to the machine.

G.

Anti-Condensation Heaters "Off-Auto" selector switch.

H.

"Phase Check" green indicating light. correct.

Light is on when machine phase rotation is

I.

Blower. Start, stop pushbuttons and green on light. This controls the motor driven blowers for cooling D.C. motors.

J.

Exciter Set. Start, stop pushbuttons, green on indicator light and phase reversal light.

K.

No. 1 M-G Set. Start, stop pushbuttons, green on light and green field light.

L.

No.2 M-G Set. Start, stop pushbuttons, green on light and green field light.

M.

No.3 M-G Set. Start, stop pushbuttons, green on light and green field light.

N.

No. 1 Thru No. 5 filter fan start-stop selector switches.

0.

No. 1 Air Compressor "Off-Auto" selector switch.

P.

No.2 Compressor "Off-Auto" selector switch.

0.

Auxiliary Transformer Temperature Alarm. above normal temperature.

R.

Frame Exhaust Fans "on-off-auto" selector switch. thermostat.

S.

Frequency Relay Tripping Switch. This is a hand reset switch operated by the overunder frequency relay.

T.

Over-Under Frequency Relay-Monitors if the machine is connected to the power line.

U.

A.C. Watt Hour Meter.

Indicates that auxiliary transformer is

"Auto" position operates from

NOTE: The order in which to operate this panel is found in text for START-UP and SHUTDOWN procedures.

2-13

EM029421-0 (en-us)

A VISUAL INSPECTION of the machine should be performed, by operator and oiler, at the beginning of each shift. A potential problem may be prevented if discovered early. The following check lists should help with the inspection.

(

GENERAL CHECK LIST for all areas of the machine: Are guards, cover plates and safety devices secured in place All wiring harness secured in proper manner All loose pieces stored in proper compartment or removed Check All hardware for tightness, missing bolts, nuts, pins, etc.

Proper lube supply to all bearings and lube points All lube piping connected and filled All lube (grease) spills wiped up The machine thoroughly CLEAN

TUB CHECK LIST- Note the following items: Hook shoe(s) adjustment with pin lock in place No obstructions in roller path or main rotating gear Trail cable in proper place

HOUSE CHECK LIST- Note the following items: Automatic lube system has adequate lube supply All gear cases have proper oil level and all filters installed Check all gearing for cracks, wear, proper lubrication, bolts, etc.

Check air compressor crankcase oil level.

( 2-14

EM029421-0 (en-us)

HOUSE CHECK LIST (continued): Main house crane hoist is not parked on a crossover All limit switches work correctly

FRONT END CHECK LIST- Check the following items: Check bucket for wear, worn, broken or missing teeth, loose or. missing pins, weld cracks Boom for cracks, bent pipes Condition of boom support ropes Intermediate boom support ropes for proper tension Condition of hoist and drag ropes Condition of fairlead components

NOTE: If any problems are found after going thru the above check lists, notify maintenance AT ONCE, so correction can be made.

TYPICAL START-UP from a completely shutdown machine. Use the controls on outside of power control room to start the air compressor, exciter set, motor blowers, M-G sets and fi Iter fans.

All starters are protected by circuit breakers for overload protection and to open circuits for maintenance.

A

~

CAUTION: DO NOT use breakers as an Off-On switch. Make sure ALL breakers are On before start-up.

Observe that the green 11 Phase Check" light is lit.

Start the air compressor units first by turning switch On.

2-15

EM029421-0 (en-us)

Next, start the motor blowers by depressing and releasing the start push button. These blowers are used in cooling the DC electric motor. Check the green indicator to be sure it is on but the sound of the blowers will tell you that they are operating. Shutdown if you hear unusual sound.

(

Now, start the exciter set by fully depressing and releasing the start pushbutton. The green indicator will light up. Observe the DC voltmeter to make sure exciter is up to operating speed. Listen for unusual sounds and shut down if necessary. Set the frame exhaust fans control on 'Automatic".

Now, start number one M-G set by fully depressing and releasing start push button. Be sure both green indicator lights are lit, and all meters are stabilized, before starting number two M-G set. In a similar manner start number two sets and number three. If unusual sound or noise is heard, shut down.

IMPORTANT NOTE: When starting the M-G sets, the Start-Stop button should be held in the "Start" position for 2-3 seconds, and then released. If the synchronous motor vacuum breaker does not stay closed when the start button is released, REPEATED ATTEMPTS TO START THE SET SHOULD NOT BE MADE. On a motor of this type, NEMA standards permit two successive starts if the motor is at ambient temperature. Before attempting another start, the vacuum breaker starting circuitry or mechanism should be corrected and proper operation verified.

Start the fi Iter fan system. Move the three position selector switch to the "Start" position momentarily and release. This will start the bleed duct fans. In approximately 5 seconds, the main fan will automatically start and the illuminated selector switch will light. The sound of the fans will tell you they are operating. Shut down immediately if unusual sounds are heard. The filter fans introduce clean air into the house to cool the operating equipment.

The fans create a positive pressure in the house to prevent dust accumulation. Be sure to operate with doors closed.

After all systems are functioning properly, leave house and proceed to the operator's cab.

Upon entering the operator's cab, observe the air pressure gauge. This gauge provides a visual reference of the air system pressure and should read from 95 to 115 psi during operation.

Press the test button on annunciator panel and all lamps should light. If a lamp doesn't light, either the lamp or fuse is bad, replace if need be. If a lamp is on, investigate the reason before start-up.

Sit in the operator's seat and get comfortable.

( 2-16

EM029421-0 (en-us)

Check the hoist, swing and drag/propel brake switches to be sure they are in the set position. Next, check the position of the hoist and drag controllers to be sure they are in neutral and no pressure on swing pedals.

IMPORTANT NOTE: This machine is equipped with an electronic rope limit control system. This system is designed to aid the operator in avoiding serious mechanical damage to the machine due to hoist or drag bucket overtravel or bucket tightlining. However, the system is not a substitute for careful operator operating procedures. The rope limit control system should be verified for proper operation on a daily basis. It is EXTREMELY IMPORTANT that the system be recalibrated after any rope or bucket rigging changes have been performed. Refer to the Marion Protection System operation manual for proper procedures.

Press DRAG MODE push button, bottom left hand on left hand control stand, then press the push button marked excitation start on right hand stand. This will energize the operating controls. Next, turn the hoist, swing and drag brake switches to release position.

Push the excitation start button again, this will release the brakes and shut off the red indicator lights. The machine is now operational.

A

DANGER:

Do not leave operator's seat unless controls are de-energized and brakes set.

The operator controls the machine, its usefulness and the crew alone thinks for it. Safety, in mind, prevents accidents. PLEASE KEEP safe operating procedures in mind at ALL times.

NOTES:

2-17

I

EM029421-0 (en-us)

Start TYPICAL DIGGING CYCLE with bucket on ground, in pit, under boom (point). If machine tends to drift (rotate) apply enough pressure on opposite swing pedal to hold machine.

(

Start dragging in bucket by pulling toward you the drag control lever (at left hand). The further the lever is moved, the faster the bucket is pulled toward the machine. Hold tension on hoist ropes by depressing the thumblatch on drag controller. If more power is needed coordinate movement of hoist and drag controls. Pull bucket in until it is full.

Then by proper movement of hoist and drag control levers, power on hoist is increased (pulled back) and power on the drag is decreased (moved forward).

NOTE: Only enough tension is kept on the drag ropes to keep the bucket from dumping.

Too much tension will cause bucket to carry near boom, add strain to boom and slow down hoist speed.

( 2-18

EM029421-0 (en-us)

As bucket clears the ground the swing pedal, which corresponds to desired direction of swing is slowly depressed. (This avoids excessive bucket and rope swing). Swing and hoist bucket at same time so that dumping height is reached at same time bucket reaches spoil.

A

CAUTION: When swinging, make sure the bucket has been raised to clear all obstructions and rear of machine has clearance.

As dump point is reached, reverse swing pedals bringing swing to a smooth stop. When machine comes to rest, the pedal should be brought immediately to neutral position (no pressure on pedals) or else the machine will start to swing in the opposite direction.

Now, release tension on drag ropes allowing bucket to dump. As bucket dumps the hoist controller must be returned, moved forward to a point of less power. Do not allow excessive amount of drag to run out.

DO NOT hold load longer than necessary to complete the dumping cycle. After material clears bucket, slowly depress swing pedal (direction desired) to start return swing to pit and at same time lower bucket into pit.

While operating, the operator should observe components in his vision and be alert for pins coming out around bucket, boom support and running ropes for broken strands, fraying, etc. The wire ropes are expendable items. Kinks cause permanent damage. Replace these ropes promptly.

Also, note any uncommon feel or noise in the machine and notify maintenance of any problems while they are still minor.

PROPEL CONTROL- Electrically, the propel equipment consists of: 1.

D.C. drive motor on each machine side

2.

A drag propel contactor and

3.

A control and timing system

The motor, one each side, independently drives its propel machinery. The drag-propel contactors electrically disconnects the drag motors from the drag generators and connects the propel motors to these generators. Thus, the drag master switch controls the propel motors when walking. Since the two sets of propel machinery are not connected mechanically, the two shoes are electrically timed or synchronized. This is done using a selsyn system that

2-19

EM029421-0 (en-us)

detects when one shoe is getting ahead of the other. The error signal from this system slows down the fast shoe and speeds up the slow shoe. Limit switches, detecting shoe position, slow the shoes during the step when shoes approach the ground and when the tub approaches the ground at the end of a step. This allows a smooth, shock-free operation. A limit switch also detects when the shoes are on PARK position.

(

GROUND PREPARATION is very important. The walking dragline requires properly prepared ground, not just in the work area, but at roadways and erection site. The tub and walking shoe must have FULL contact with the ground. When machine weight distributes over the entire tub area and walking shoe, a moderate ground bearing pressure is obtained.

The ground supporting a dragline must be as near level as possible. Sand, clay and top soil level easily with a blade or grader. Remove large rocks and rock formations. Where this seems impossible, cover working area with a sufficient depth of fill dirt to cover rocks.

Sharp rocks or boulders cause load points that damage bottom plates and bulkheads of the tub and walking shoe.

During the walking step cycle, the rear of the tub lifts off the ground. The front edge of the tub supports about 20 percent of the machine weight. As the forward edge of the tub drags to the rear in dry, sandy or powdery soil; this soi I tends to pile up or roll ahead of the trailing edge. To relieve this condition to some degree, rest the bucket on the ground and allow the hoist rope to support bucket rigging during this sliding portion of the walking cycle.

Then as the tub lowers to the ground, pick up the bucket. (See NOTE under RAMPING for non-level conditions.) When ground continues to roll ahead of the tub and tub lowers onto this roll, the front of the tub is too high. In this case swing machine 30 or 40 degrees to one side and propel one step. This act spreads the pile or roll over a large area. Then return to original line of travel and propel.

The Marion dragline design incorporates a calculated balance between boom length, boom angle and allowable load at bucket and machine weight and ballast. During normal digging cycles, the center of gravity shifts from front to rear within a specific area called the kern.

As long as the center of gravity falls within the kern, the machine maintains stability andrelatively even ground bearing pressure over the entire tub area. If for any reason, the digging radius or allowable load increases and the center of gravity goes beyond the kern to the perimeter of the tub; this increased rim pressure causes the tub edge to cut into the ground.

Rotating the machine in this condition causes the ground supporting the tub to form into the shape of a cone. This cone results in an undesirable rocking motion and an unstable machine. This also causes concentrated ground bearing pressure at the center of the tub.

A

CAUTION: 00 NOT allow bucket to be jerked off ground.

( 2-20

EM029421-0 (en-us)

-.The walking mechanism lowers both walking shoes to contact ground at same time (level ground). The walking shoes swivel allows for ground unevenness without damage to walking mechanism. If one of the walking shoes does not strike ground, or steps in a soft spot that will not support machine weight, the machine will rotate around tub side, in this case operator should stop the step before machine lifts and reverse walking step to return to normal position. Swing machine to walk around soft spot.

RAMPING the machine from one level to another requires exercising great care. Walking the machine subjects the tub and upper frame to stresses much greater than a normal digging operation. Ramps for up and down propelling should be no greater than 10 percent in grade. Ramps for a new machine should be no greater than a 5 percent grade.

A

CAUTION: When propelling up a ramp, lower the bucket to the ground. THIS IS A MUST. When propelling down a ramp, carry the bucket in the air 100 feet from the machine. Do not heel the bucket. At other times carry the bucket suspended and pulled in approximately 50 feet from the boom foot. Set the hoist and drag brake. The machine design allows travel up or down a grade of 10 percent and a traverse of a 5 percent grade. However, avoid this latter if at all possible.

Before OPERATING THE WALKING MECHANISM the bucket must be raised and held approximately 50 feet from boom foot. Swing rear of machine into direction of travel.

Place trail cable in a safe position. DO NOT use walking shoes to pull (move) trail cable.

To transfer machine to propel, first move drag-propel brake switch to the SET position, next, press propel transfer push button and hold until amber propel mode light is on. Then, move drag-propel brake switch to RELEASE. Finally, press excitation start push button to energize drag controller and release propel brake. The drag brake light should remain lit.

Check drag master switch function to be sure ALL transfer operations are complete and drag machinery is de-energized. THIS IS IMPORTANT since this check can avoid possible bucket or boom damage if drag motion is still energized and master switch is moved full on.

When the first step is indicated and the shoes move off park position, the swing and hoist brake automatically SET; if not already manually set.

During a long walk, it is often necessary to swing machine to change direction of travel and/or to reposition the bucket with the hoist. This may be accomplished without transferring to drag by stopping shoes in PARK position, CLEAR TO SWING light lit, drag-propel brakes SET, RELEASE hoist and/or swing brakes, then press the EXCITATION ON push button. To continue propelling, RELEASE the drag-propel brakes and press EXCITATION ON push button.

2-21

EM029421-0 (en-us)

(

The shoes may be automatically stopped in PARK position in the following manner: When the shoes leave the ground after the last desired step, press the SHOE PARK push button and hold until the shoes reach the PARK position. The brakes automatically set and the drag controller de-energizes. While holding the SHOE PARK push button depressed, move the drag-propel brake selector switch to SET and return the master switch to neutral.

The propel machinery can be moved in either forward (normal) or reverse direction. The selsyn position indicators located in the operator's cab, on warning panel, show the position of each mechanism on a dial.

If at any time the walking mechanism is not synchronized, the propel error warning light on warning panel will light up. To synchronize mechanism the propel error bypass push button, on drag stand, is used to override the synchronization circuit. The shoes are then realigned for parking.

WALKING MACHINERY - Two propel machine assemblies are located at each machine side. These assemblies operate independently except for an electrical (selsyn) connection that synchronizes the walking step.

Phase 1 -Shoe on Ground·

Park Position

Movement of Machine

I I~

~ 97~:0

I

·-

---

•

l

'

...

_I

Phase 3

Phase 2

( 2-22

EM029421-0 (en-us)

Each assembly consists of an eccentric, a walking arm with stabilizer arm and walking shoe.

The walking arm connects to the walking shoe by a ball swivel joint that allows the shoe to swivel in all directions and have limited lateral movement. This way the shoe adapts itself to the propel machinery. A walking step is created by rotating the main propel shaft and eccentric. The eccentric top always turns toward machine rear. The walking arm turns on the eccentric arm and when restricted by the stabilizer arm, generates the walking step motion of each side.

During the first eccentric quarter turn, the walking shoe moves from the raised position toward machine rear. The shoe continues to move rearward and down until the shoe contacts the ground behind the machine center of gravity. Just before eccentric reaches the second quarter turn of rotation, the machine rear and tub rear edge raises and moves slightly forward. This motion raises tub out of any depression formed while digging and breaks any suction under the tub.

In the second quadrant of eccentric rotation, the shoe moves down and toward machine front. This causes machine to be propelled to rear, dragging tub front edge.

The third quarter turn of eccentric completes the propelling step. Machine and tub slowly lower to the ground.

The last or fourth quarter turn returns shoe to raised or park position.

The shoe return mechanism align shoes parallel to the rotating frame when in park or raised position.

Refer to DRAG MODE on how to get the machine from the propel to drag mode.

TYPICAL PARTIAL SHUTDOWN for shift change or lunch break. At end of each shift, the operator should swing machine one complete revolution. This will change position of rollers in the roller circle for even wear.

For this type of shutdown, only the primary operating controls (hoist, drag and swing) will be deactivated. Lower bucket to ground and return all controllers to neutral.

Place hoist, drag and swing brake selector switches in the set position. Make sure all controllers are in neutral position. Now, fully depress and release the emergency stop push button located on right hand panel. This will de-energize the primary controls.

To COMPLETELY SHUTDOWN follow procedure just described, then leave cab and go to the control panel on outside of power control room.

2-23

EM029421-0 (en-us)

Fully depress and release the three M-G stop push buttons. Depress the blowers, and exciter set stop push buttons. Turn five filter fan and frame exhaust fan switches to "off".

Turn two air compressor switches to "off".

( \

The machine is now shutdown to a point where inspection, maintenance, etc. can be performed on rotating machinery. Keep in mind, incoming electrical power is on to transformers, cabinets, collectors rings, etc.

A

DANGER:

Do not inspect areas containing electrical components unless power to components is isolated and locked out. Observe all signs.

( 2-24

EM029421-0 (en-us)

SECTION 3 LUBRICATION INDEX Page lubrication Fittings ........................................ 3-1 Anti-Friction Bearings ...................................... 3-1 Open Gears ............................................... 3-1 Enclosed Gear Cases ........................................ 3-1 Wire Rope Pendant lubrication ............................... 3-2 Check list ............................................... 3-2 lubrication Specifications: Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oils ....................... -........................

Gl- Gear lubricants (Oil Type) ........................

Description of Oil and Grease Classification ................

Special Products .....................................

Approved Products ...................................

3-3 3-3 3-4 3-5 3-8 3-8

lubrication Points: Propel Machinery (1 of 2) ............................. 3-9 Center Journal ..................................... 3-11 Rotating Machinery (1 of 5) ........................... 3-11 Roller Rail ........................................ 3-12 Hoist Machinery .................................... 3-12 Drag Machinery .................................... 3-13 Fairlead .......................................... 3-14 Tri-Structure ...................................... 3-14 Boom ............................................ 3-15 Miscellaneous Points ........•........................ 3-16 Automatic lubrication System .............................. 3-18 Alarm Reset ............................................. 3-18

EM029421-0 (en-us)

Section 3- Lubrication (cont.)

Page

(

Auto Lube for Propel Machinery ............................. 3-19 Auto Lube for Rotating Frame .............................. 3-20 Auto Lube for Wire Rope ................................... 3-21 Auto Lube for Open Gears .................................. 3-22 Auto Lube for Front End ................................... 3-23 Lubrication of Rotating Gear Case ............................ 3-27 Tell-Tale Filter ........................................... 3-27 Hoist, Drag and Propel Gear Cases ............................ 3-28 Tell-Tale Filter ........................................... 3-28 Standard Lubrication Installation ............................. 3-30 Adjusting and Mounting of Lincoln Injector .................... 3-31 Assembly of Hose Fittings .................................. 3-32

(

EM029421-0 (en-us)

SECTION 3 LUBRICATION

Application of CORRECT lubricant in the CORRECT amount thru a CORRECT program is required for the successful operation of any machine. Proper lubrication reduces maintenance and increases component life. Absence of proper lubrication wears moving parts quickly and failure results.

LUBRICATION FITTINGS on plain and anti-friction bearings not served by the automatic lubrication system are hydraulic type push on fittings, 1/8" or 1/4" as per MPSD standard.

When contamination creates a problem, as in slow speed bearings using labyrinth seals, new grease may be added until clean grease seeps out of the seal. When a bearing runs excessively warm due to overfilling, remove the pressure fitting and allow excess lube to escape.

Allow bearing to operate and purge excess lube for 10-15 minutes, then replace fitting.

ANTI-FRICTION BEARINGS, grease lubed, requires the full quantity of lube as specified in the Lubrication Specifications. Ball and roller bearings require only a relatively small amount of lube and relube intervals are generally long with good seals. Accurate predetermination of when to add new grease is Impossible. Grease in a bearing generally deteriorates gradually, not suddenly. Thus only a small amount need be added. A small amount of lube applied every 500 operating hours, unless otherwise specified, maintains adequate lubricating properties.

OPEN GEARS and pinions require a constant coat of a good grade of lubricant.

ENCLOSED GEAR CASES must maintain the recommended lubricant level. Check the dipstick or plug at regular intervals. When a seasonal change of lube occurs, pump used oil into a drum for final disposal. Drain all remaining oil from case thru drain plug opening. Flush gear case with fuel oil or light lube oil after draining. Refill with proper lube.

A

CAUTION: EXTREME TEMPERATURE OPERATION of this machine below -20 degrees F. (-29 degrees C.) or above 110 degrees F. (44 degrees C.) requires special lubrication recommendations. Contact your local supplier or Marion Power Shovel Division at Marion, Ohio 43302.

Give full particulars concerning specific conditions of your operation.

3-1

EM029421-0 (en-us)

NOTE: Unusually dusty or dirty atmosphere, high humidity and extreme temperatures alter the effective life of a lubricant. Therefore, it shall be the responsibility of the owner/operator to determine the most effective lubricant interval according to existing environmental conditions for all components, bearings (plain and anti-friction), gears, gear cases, etc.

(

WIRE ROPE PENDANT LUBRICATION dislodges with the movement of strand against strand. This permits moisture to enter and causes deterioration of the rope. The area where greatest deflection occurs is at or adjacent to the socket connection. Experience shows this the most likely point of boom point support bridge strand rope failure. To avoid this condition and increase useful life expectancy of the bridge strand support rope apply wire rope lube to the socket area using the hand spray.

CHECK LIST for initial lubrication start-up and any inspection following: All grease piping connected and filled.

Proper lube supply to all bearing and lube points.

NOTE: All anti-friction bearings and bushings have correct initial lube fill per manufacturer's recommendations.

Proper oi I level in all gear cases.

Open and semi-enclosed gear teeth coated with lube.

Automatic lubrication system with adequate lube supply.

USE ONLY CLEAN AND PROPER LUBRICANT- KEEP IT CLEAN Selection of proper lubricant remains of the utmost importance. Improperly lubricated bearings, gears, couplings, and other precision parts quickly fail. For this reason, lubricants selected in accord with the ASTM Standards are recommended. These standards were compiled in cooperation with major petroleum suppliers to insure the consumer of exact supply to specific requirements regardless of source. DO NOT MIX GREASES OR BRANDS OF GREASE. We recommend you advise your petroleum supplier of the following information to assist him in selecting the proper product for each application on this machine.

Final acceptance of all lubricants supplied to this standard will be based upon satisfactory performance in its intended application and does not relieve the supplier of performance responsibility of brand name products.

( 3-2

EM029421-0 (en-us)

CAUTION: Contact with or swallowing of lube products can prove harmful.

Lubrication system operates under pressure. Relieve pressure in system before performing maintenance.

A

LUBRICATION SPECIFICATIONS- GREASES CODE OR SYMBOL NO. Penetration Worked 60X Summer, NLGI Winter, NLGI

ASTM

MPG or TEST

RGL

D-271

2

semifluid

OGL TYPE B TYPE H

0

Penetration Worked 10,000, Max. Change

D-217

10%

Dropping Point, Min. °F (°C)

D-566

350 (177)

Base Oil Viscosity @ 210°F (99°C), Min.

D-446

75

Oxidation Stability Max. psi (kPa) Drop-100 Hrs.

D-942

10 (68)

Water Resistance Max. Loss @ 100°F (38°C)

D-1264

20%

10%

10%

Texture

Visual

Buttery

Adhesive

Tacky

35 (16)

35 (16)

35 (16)

EP Timken, Min. OK, lbs. (kg)

sus

325 (163)

140

sus

2000

sus

2000

sus

SPECIFICATION- OILS CODE OR SYMBOL NO.

ASTM or Test

MO

OIL

PO

Pour Poipt °F (°C), Max.

Summer Winter

D-97

5 (-15) 0(-18)

15 (-9) 15 (-9)

Flash Point °F (°C), Min.

Summer Winter

D-92

450 (232) 420 (216)

410 (210) 410 (210)

D-446

3-3

150 (66) Min.

EM029421-0 (en-us)

CODE OR SYMBOL NO.

ASTM or TEST

MO

OILS PO

D-446

60-68 51-55

43 43

Viscosity Index, Minimum

D-567

90

101

Rust Test- 48 Hrs., Syn. Sea Water

D-665

None

Viscosity@ 210°F (99°) SUS

Summer Winter

Summer Winter

SAE Viscosity No.

30 20W D-611

Analine Point Minimum

(

10 10 215

GL- GEAR LUBRICANTS (OIL TYPE) CODE OR SYMBOL NO.

ASTM or TEST

GL-90

GL-140

GL-200

GL-250

Pour Point °F (°C) Max.

D-97

0 (-18)

10 (-12)

20 (-7)

30 (-1)

Flash Point °F (°C) Minimum

D-92

Viscosity@ 100°F (38°C) SUS (Min.)

D-446

1100

2000

3500

4500

Viscosity@210°F (99°C) SUS

D-446

80-120

120-180

180-120

210-260

Viscosity Index (Min.)

D-567

80

80

80

80

6 EP

7-8 EP

8 EP

8a

SAE Viscosity No.

90

140

140/120

250

EP Timken, Min. OK

65

65

65

65

2

2

2

2

410(210) 410(210) 410 (210) 410 (210)

Equiv. AGMA lubricant No.

Copper Corrosion Max.

D-130

Oil Temperature oc Gear lubricant Gl-90 Gl-140 Gl-200 Gl-250

Min. -18 -12 -7 -1

oF Max. 41 52 60 66

Min. 0 10 20 30

Max. 105 125 140 150

( 3-4

EM029421-0 (en-us)

DESCRIPTION OF OIL AND GREASE CLASSIFICATION

CODE

NAME

DESCRIPTION

MPG

Multipurpose Grease

A well manufactured E.P. grease having good resistance to both heat and water, possessing good mechanical stability and oxidation resistance. It must be suitable for use in Farval, Lincoln and Trabon automatic dispensing systems. It shall be free of corrosive and deleterious foreign matter of any kind.

Special products not meeting the requirements of the Engineering Standard may be required for operation at sub-zero ambient temperatures.

MPSD should be consulted regarding products intended for service at low ambient tern peratu res.

USES - Anti-friction bearings both packed and gun lubricated, chassis and plain bearings and central lubricating systems.

RGL

Regular Gear Lubricant

Semi-fluid greases having just enough body to retain them in a semi-enclosed case. It must have good adhesive, load carrying and non-channeling properties.

USES - Semi-enclosed gear cases.

OGL

Open Gear Lubricants

Either of two types of product may be specified.

They are intended for use on open gearing where retention is a problem. Both must be adhesive in nature and resist dripping from or flinging off the exposed gearing either idle or in motion. They must be water and corrosion resistant and have E.P. properties.

1.

Type B must be suitable for application without heat or diluent and should be suitable for use in automatic dispensing systems if required.

3-5

EM029421-0 (en-us)

CODE OGL

DESCRIPTION

NAME Open Gear Lubricants

2.

Type H is usually an asphaltic type product requiring heat or a diluent for application.

Diluents used in solvent cut-back products must have a fast evaporation rate and be nonflammable. They must not show separation in storage or service and should be suitable for use in automatic dispensing systems at low ambient temperatures.

USES - Open gears.

EO

Engine Crankcase

Diesel engine crankcase oils may be one of two (2) viscosity grades, SAE 20-20W or 30.

1.

Oil suitable for use in Cummins Engines of at least MIL-L-2104A, Sup. 1 level.

2.

A qualified series 3 oil for use in Caterpillar Engines.

MO

Motor Oil

A rust and oxidation inhibited non-detergent motor oil suitable for use in DeVilbiss and/or Ingersoll Rand piston type reciprocal air compressor crankcase lubrication.

HL

Hand Lubrication

Use oil (MO) above or a general machine oil (S-SAE 30, W-SAE 20W).

GL

Enclosed Gear Case

Use the same weight oil throughout the year if possible. Use as viscous a product as possible for maximum gear life.

Loading shovels and smaller machines of crawler type: 1.

Use GL-140 in lower frame propel gear cases and other gear cases outside machinery house.

2.

For gear cases inside machinery house in older machines where oil is pumped, use GL-90 in winter and GL-140 in summer.

3-6

(

EM029421-0 (en-us)

CODE GL

DESCRIPTION

NAME Enclosed Gear Case

3.

Inside machinery house, where oil is not pumped, use GL-200 except where freezing temperatures rarely or never occur, use GL-250.

For large shovels and walking draglines: 1.

For crawlers, use G L-140.

2.

For gear cases inside machinery house: a.

Use GL-200 where there are no pumps or where V-belt drive pumps are used.

b.

Use G L-250 instead of G L-200 where temperatures rarely go below freezing.

c.

Use GL-140 with older type pumps.

On new machines, oil should be drained after first 60 days of operation and replaced with new oil.

Thereafter, change oil once a year, or when determined necessary by oil supplier. Oil should be checked for contamination every 30 days.

PO

Pneumatic Oil

Petroleum oil especially compounded for use in air line oilers or built in lubricators having the correct viscosity, low pour point, emulsifying ability, film strength and free of deposit forming tendencies.

It should not cause swelling or deterioration of rubber or leather seals and gaskets.

EMG

Electric Motor Grease

Electric motor bearing grease meeting the requirements of G.E. Specification D6A2C5 or Westinghouse equivalent.

In addition to the aforementioned products the following lubricants may also be required.

No specification or standard for these products have as yet been prepared.

3-7

EM029421-0 (en-us)

(

SPECIAL PRODUCTS:

\

WR L- Wire Rope Lubricant. May be of either solvent cut-back asphaltic water resistant type or penetrating oil type containing corrosion and rust preventatives, anti-wear and other suitable polar additives. The former are preferred for wire rope operating in extremely wet environments while the latter are preferred for normal shovel and dragline operations where contamination of the wire with highly abrasive dust particles is the primary problem. *WCL- Walking Cam Lubricant. A special product designed to lubricate bronze bushings. These bushings, up to 120" in diameter, are subjected to loads in excess of 2,000 psi in some areas.

APPROVED PRODUCTS:

* Jesco "Walking Cam Lubricant" Mobil Oil "Mobiltac E" Bel-Ray "ALO-Open Gear Lubricant" Whitmore "Liquid Gear Composition"

PLEASE STORE LUBRICATION DRUMS ON SIDE WITH OPENING UP. FILTER ALL 01 L BEFORE ADDING TO SYSTEM.

( 3-8

EM029421-0 (en-us)

NAME OF PART

TYPE

NO. OF POINTS

LOCATION

LUB. SYM.

METHOD & FREQUENCY

LUBRICATION OF PROPEL MACHINERY (1 of 2)

Walking Arm Eccentric

Bushing

16

In O.D. of Bushing

WCL

Automatic

Stabilizer Arm, Top

Bushing

1

In End of Pin

WCL

Automatic

Stabilizer Arm, Bottom

Bushing

1

In O.D. of Bearing Boss

WCL

Automatic

Shoe Swivel Ball Joint

Bushing

6

In O.D. of Spherical Bushing

WCL

Automatic

Lateral Ball Joint Shaft

Bushing

4

In End of Shaft

WCL

Automatic

Main Propel Outer Bearing

Bushing

8

In O.D. of Bearing Boss

WCL

Automatic

Main Propel Inner Bearing

Bushing

8

In O.D. of Bearing Boss

WCL

Automatic

Main Propel Pinion Bearing

AntiFriction

2

Piped to Side of Bearing Housing

MPG

Hand, 500 Hrs.

8

Drip on Gear

OGL

Automatic

Propel Gear and Pinion Propel Shaft Spline (In Eccentric)

Use Molycote M-8800 before Assembly Use OGL Type OGL B after Assembly; at Inside Spoke of Eccentric

3-9

6 Mo., Hand Keep Coated

EM029421-0 (en-us)

NAME OF PART

TYPE

NO. OF POINTS

LOCATION

LUB. SYM.

Use Molycote M-8800 before Assembly Use OGL Type OGL B after Assembly; in Boss of Gear Hub

Propel Shaft Spline (In Gear)

Propel Motor Coupling

1

Fill thru Plug in Flange

MPG

METHOD & FREQUENCY

6 Mo., Hand Keep Coated

Hand, 3 Mo. Keep Filled

Propel Motor Extension Shaft

AntiFriction

2

From Gear Case

GL

1st and 2nd Intermediate Propel Shafts

AntiFriction

4

From Gear Case

GL

1

At Propel Case Hand Pack before Assembly

OGL Type B

6 Mo., Hand Keep Coated

Fill at Air Filter

GL

Check Weekly at Dipstick 300 U.S. gal. cap., each case

2

In Motor End Bell

EMG

Hand (see E leetrical Section)

4

In Top of Spring Case

MPG

Weekly, Hand

Propel Coupler Spline

Propel Gear Case

Propel Motor

AntiFriction

Shoe Return Spring

(

Rope Deflector Sheave on Shoe Return

Bushing

2

In End of Roller Shaft

MPG

Weekly, Hand

Rope Deflector Sheave Swivel on Shoe Return

Bushing

4

In Bracket Bosses

MPG

Weekly, Hand

( \

3-10

EM029421-0 (en-us)

(

NAME OF PART

TYPE

NO. OF POINTS

Sho~

Plain

2

Roller

LOCATION In End of Roller Shaft

LUB. SYM.

METHOD& FREQUENCY

MPG

Weekly, Hand

LUBRICATION OF CENTER JOURNAL Center Journal Bearing

AntiFriction

4

In Top of Bearing Housing

MPG

Automatic

Center Journal Bushing

Bushing

8

In Top of Bearing Housing

MPG

Automatic

Retainer Assembly Bushing Aligning Pin

4

In O.D. of Retainer

MPG

Automatic

MPG

Self-Lubrieating

Collector Ring Mount- Bottom

Nylatron Bushing

Lube at Assembly

Collector Ring Mount-Top

Oilite Bushing

In Top of Housing

Self-lubricating

Auxiliary Collector Ring

None Required

LUBRICATION OF ROTATING MACHINERY (1 of 5) Main Rotating Gear Case

Fill at Air Filter to Oil Level Plug in side of Case

GL

280 U.S. gal. cap., Check Weekly

Plug in Coupler Flange

MPG

3 Mo., Hand Keep Filled

Drip on

OGL

Automatic Keep Coated

Main Rot. Shaft Top Bearings

AntiFriction

From Gear Case

Motor Et<tension Shaft Bearings

AntiFriction

From Gear Case

Rotating Motor Coupling Rotating Pinion and Gear

2

3-11

EM029421-0 (en-us)

NAME OF PART

NO. OF POINTS

TYPE

Main Rotating Shaft Spline and Split Thrust Washer

LUB. SYM.

METHOD & FREQUENCY

Fitting at Top of Swing Case

MPG

Hand, 500 Hrs.

LOCATION

Rotating Motor

AntiFriction

2

In Motor End Bell

EMG

Hand (see Electrical Section)

Main Rot. Shaft Bottom Bearing

AntiFriction

1

In Top of Bearing Sleeve

MPG

Automatic

OGL

Automatic

(

LUBRICATION OF ROLLER RAIL 6

Roller Rail

Drip on

LUBRICATION OF HOIST MACHINERY Hoist Drum Support Bearing

AntiFriction

2

In Bearing Housing

MPG

Automatic

Intermediate Hoist Shaft (In Case)

AntiFriction

3

From Gear Case Fi II at Air Filter

GL

95 U.S. gal.

Intermediate Hoist Shaft (Inboard)

AntiFriction

3

In Bearing Retainer

MPG

Hoist Motor Extension Shaft

AntiFriction

10

From Gear Case

GL

each case, Check Weekly at Dipstick Keep full Automatic

Hoist Motor Coupling

5

Plug in Coupling Flange

MPG

Hand, 3 mos.

Keep Filled

Hoist Gear and Pinions

8

Drip on

OGL

Automatic

( 3-12

EM029421-0 (en-us)

( NAME OF PART Hoist Motor

TYPE AntiFriction

NO. OF POINTS 10

Hoist Rope

LUB. SYM.

METHOD & FREQUENCY

In Motor End Bell

EMG

Hand (see E leetrical Section)

Spray on at Tri-Structure and Boom

WRL

Semi-auto, 8 Hrs.

LOCATION

LUBRICATION OF DRAG MACHINERY Drag Drum Support Bearing

AntiFriction

2

In Bearing Retainer

MPG

Automatic

Intermediate Drag Shaft (In Case)

AntiFriction

2

From Gear Case Fill at Air Filter

GL

95 U.S. gal. each case, Check Weekly at Dipstick, Keep Full

Intermediate Drag Shaft (Inboard)

AntiFriction

2

In Bearing Retainer

MPG

Automatic

Drag Motor Extension Shaft

AntiFriction

8

From Gear Case

GL

Drag Motor Coupling

4

MPG

Hand, 3 Mos. Keep Filled

Drag Gear and Pinions

4

Plug in Coupler Flange Drip on

OGL

Automatic

In Motor End Bell

EMG

Hand (see Electrical Section)

Spray on at Fairlead

WRL

Semi-auto, 8 Hrs.

1,'.·

Drag Motor

Drag Ropes

AntiFriction

8

3-13

EM029421-0 (en-us)

NAME OF PART

TYPE

NO. OF POINTS

LOCATION

LUB. SYM.

METHOD& FREQUENCY

(

LUBRICATION OF FAIRLEAD Top Fairlead Sheave

AntiFriction

2

In End of Shaft

MPG

Automatic

Bottom Fairlead Sheave

AntiFriction

2

In End of Shaft

MPG

Automatic

Swivel Journal Top

Bushing

4

Swivel Frame

MPG

Automatic

Swivel Thrust Top

Washer

4

Side of Collar

MPG

Automatic

Swivel Journal Bottom

Bushing

4

Swivel Frame

MPG

Automatic

Swivel Thrust Bottom

Washer

4

Swivel Frame

MPG

Automatic

Plain

2

End of Pin

MPG

Hand, 6 Mo. & Before Use

Fairlead Foot Pin

LUBRICATION OF TAl-STRUCTURE Boom Support Link Pin

Bushing

2

End of Pin

MPG

Automatic

Boom Support Ropes Connection

Bushing

6

End of Pins

MPG

Automatic

Boom Raising Sheaves (in Rope Assembly)

Bushing

2

In Hub of Sheave

MPG

Hand, 6 Mo. & Before Use

Intermediate Support Ropes Link

Bushing

6

End of Pins

MPG

Automatic

( 3-14

EM029421-0 (en-us)

TYPE

NO. OF POINTS

Boom Raising Sheaves (Front)

Bushing

Boom Raising Sheaves (Rear) Hoist Deflecting Sheaves

NAME OF PART

LOCATION

LUB. SYM.

METHOD& FREQUENCY

2

End of Pin

iv1PG

Hand, 6 ivio. & Before Use

Bushing

2

End of Pin

MPG

Hand, 6 Mo. & Before Use

AntiFriction

2

End of Shaft

MPG

Automatic

8

2 Each Dam per

MPG

Hand, 6 Mo.

Boom Support Rope Dampers Hoist Rope F Ioat Sheaves

Bushing

2

End of Shaft

MPG

Automatic

Rope Retaining Shaft - F Ioat Sheaves

Bushing

2

End of Shaft

MPG

Hand, Monthly

Plain

2

End of Shaft

MPG

Hand, 6 Mo. & Before Use

Foot Pin

LUBRICATION OF BOOM Point Sheaves

AntiFriction

2

End of Shaft

MPG

Automatic

Front Trunnion Bearing Block

Bushing

2

In Hub of Bearing Block

MPG

Automatic

Rear Trunnion Bearing Block

Bushing

2

In Hub of Bearing Block

MPG

Automatic

Rear Trunnion Thrust

Thrust Washer

3

In Hub Flange of Bearing Block

MPG

Automatic

Intermediate Support Ropes Connection

Bushing

6

End of Pins

MPG

Automatic

3-15

EM029421-0 (en-us)

(

NAME OF PART

LOCATION

LUB. SYM.

METHOD & FREQUENCY

8

2 Each Damper

MPG

Hand, 6 Mo.

Bushing

4

End of Pins

MPG

Automatic

Plain

2

End of Pins

MPG

Hand, 6 Mo. & Before Use

TYPE

Rope Damper Boom Support Ropes Connection Boom Foot Pins

NO. OF POINTS

( \

LUBRICATION OF MISCELLANEOUS POINTS Filter House

AntiFriction

5

In Motor End Bell

EMG

Hand (see Electrical Section)

F i Iter Ducts

AntiFriction

10

In Motor End

EMG

Hand (see E leetrical Section)

Fans

Pillow Block Bearing

10

In Bearing Housing

MPG

Hand, 500 Hrs.

Operator's Seat

Jack Screw Shaft

Under Seat

Light Oil

Hand, as Required

Operator's Seat

Swivel Joint

1

Base

Light Oil

Hand, as Required

Swing Pedals

Needle Bearings

2

Under Floor

MPG

Hand, 500 Hrs.

Main Traveling Crane

AntiFriction

8

End of Axle Pins

MPG

Hand, as Required

Jib Crane

Bushing

4

End of Shaft

MPG

Before Use

Rear House Doors Cam Followers

AntiFriction

32

End of Shaft

MPG

Hand, 12 Mo. & Before Use

( 3-16

EM029421-0 (en-us)

TYPE

NO. OF POINTS

Bushing

LOCATION

LUB. SYM.

METHOD & FREQUENCY

16

At Sheaves

MPG

Hand, 12 Mo. & Before Use

Rear House Doors Actuator Hyd. Reservoir

1

Fluid Level Gauge in Reservoir

MPSD Spec.

ML-57

Capacity 20 U.S. Gal. (Check with Cyl. Full & in Closed Position)

Auxiliary Rope Winch

2

At Top of Gear Case

GL

Change at 6 Mo., Fill to Oil Level Plug

In Housings

MPG

Hand, 12 Mo.

HL

Hand, 6 Mo.

NAME OF PART Rear House Doors Actuator Sheaves

Auxiliary Rope Winch Drum Bearings

AntiFriction

4

Front Cab Window Rollers

Trolley

2

Float Sheaves on House Roof

Bushing

2

End of Shaft

MPG

Automatic

Rope Retaining Shaft - F Ioat Sheaves on House Roof

Bushing

2

End of Shaft

MPG

Hand, Monthly

3-17

EM029421-0 (en-us)

AUTOMATIC LUBRICATION SYSTEM is divided into five parts. The control panels and supply drums are located on deck, at front of machine. The systems are propel, rotating frame, hoist and drag rope spray, open gears, and front end.

( \

The auto lube lamp, on operator's warning panel, will light and the alarm sounds for the inoperative system when: Any main line to an injector breaks The air supply fails The supply line is blocked

A lube drum empties or the pump cavitates A pump fails The control system breaks down

Pushing ALARM RESET button silences the alarm and resets system for continued service.

CHECK OUT the causes previously mentioned before continuing.

When installing, servicing or repairing auto-lube equipment: KEEP IT CLEAN. Keep ALL lines free of dirt. Bleed ALL air and pre-fill lines with lube before placing into operation.

To pre-fill, disconnect lines at bearing ONLY. Remove cap on each injector face and expose grease fitting. Fill line from injector to bearing with hand pump until lube flows from the hose. Connect hose to bearing and fill bearing. (The auto-lube system is not designed to provide initial filling of bearing, only to provide replenishing supply.)

Remove ALL plugs on main supply line, one at a time, including injector block end plugs.

Pump lube into system until ALL air bleeds out and lube flows from opening. Proceed until ALL plugs have been removed; ALL lines filled and ALL plugs REPLACED. With these steps complete, the system is ready for automatic operation.

NOTE: Do not use pipe unions on boom and gantry, hose ends work well here. Allow slack where needed for movement. Avoid sharp bends.

( 3-18

EM029421-0 (en-us)

AUTO LUBE FOR PROPEL MACHINERY supplies main propel shaft inboard and outboard bearings. It also supplies the walking cam, stabilizer and shoe swivel on each walking arm. This dual line system operates during propel or walking cycle only and its control is set to provide 20 seconds between pumping cycles. Alarm timer set for 60 seconds sounds on failure. Air pressure is regulated at 80 psi and system pressure switch setting is 2500 psi.

The system uses a 400 pound drum of WCL.

Air

I I

I

I

Line 2

I I

I

Line 1

I

I

I I

I

_ _ _j L---- - - - - ._. . .--=---+--__.

Stabilizer Ball Joint

Line 1

Line 1

Line 2

Line 2

Outboard Bearings

Inboard Bearings

Line 1 Line 2 Total Points Serviced- 88

SCHEMATIC AUTO LUBE- PROPEL

3-19

f

EM029421-0 (en-us)

AUTO LUBE FOR ROTATING FRAME supplies the center journal, rotating machinery bearings, hoist and drag drum bearings and hoist and drag intermediate shaft inboard bearings. The system cycles Line A once every 15 minutes when digging and Line B once every 3-3/4 minutes during propel. The alarm is set for 100 seconds. The air pressure regulator is set at 80 psi. The end-of-line pressure switches are set at 2500 psi. The system uses a 400 pound drum of MPG grease.

A

(

CAUTION: This system contains three shut-off valves for isolating segments for maintenance. For system to supply bearings with proper lube, valves must be open during machine operation.

Control Panel Gauge Air Line

Pressure Switch Line B

Rotating Bearing Rotating Bearings

Drag Drum Shaft

& Int. Drag Shaft Hoist Drum Shaft & Int. Hoist Shaft

Rotating Bearings 18 Points Serviced in Dig Mode 12 Points Serviced in Propel Mode Total Points Serviced- 30

SCHEMATIC AUTO LUBE- ROTATING FRAME

( 3-20

EM029421-0 (en-us)

AUTO LUBE FOR WIRE ROPE, manual operated, supplies spray to the hoist rope at top of tri-structure and at boom point. The drag rope is sprayed at the fairlead sheaves. Set air pressure regulator at 50 psi. Open air valve first. Next, open ONLY ONE of the three line valves at a time as rope is being payed out the longest distance. Lube the moving rope(s) every 8 hours or less, depending on site conditions. System uses a 400 pound drum of wire rope lube. DO NOT USE GREASE. After the hoist and drag ropes are lubed, close the air valve.

A

CAUTION: This system contains two shut-off valves for isolating sections for maintenance. For system to supply WRL to ropes, valves must be open during lubing operation.

Hoist Ropes (Tri-Structure)

Hoist Rope (Boom Point)

Upper Sheaves

Drag Ropes (Fairlead) Hoist Rope Valve Lower Sheaves Shut-off Valves

Air

Total Points Serviced- 8

SCHEMATIC AUTO LUBE - ROPE LUBE

3-21

EM029421-0 (en-us)

AUTO LUBE FOR OPEN GEARS supplies the roller circle rails, hoist and drag gears and swing pinions thru Line A which pumps ONLY when digging. The main propel gear and pinion obtain supply from Line B ONLY when propelling. The system time cycle is 10 minutes in dig and 2-1/2 minutes in propel. Alarm is set at 120 seconds. Air pressure is regulated at 80 psi. End of line pressure switches are set at 2500 psi. This system uses a 400 pound drum of OGL.

A

(

CAUTION: This system contains three shut-off valves for isolating segments for maintenance. For system to replenish OGL on gearing as needed, valves must be open during operation.

Line B Rails RH Propel Gear RH

Line A Shut-off Valve {Typ, 3 Places) Swing Pinion

Swing Pinion

Swing Pinion

Line A Pressure Switch

Swing Pinion Line A Rails LH

Line B

28 Points Serviced in Dig Mode 16 Points Serviced in Propel Mode Total Points Serviced- 44

SCHEMATIC AUTO LUBE -OPEN GEARS

( 3-22

EM029421-0 (en-us)

AUTO LUBE FOR FRONT END supplies the tri-structure, fairlead, boom and house roof float sheaves. The system time cycle is 15 minutes. Alarm is set at 150 seconds. Air pressure is regulated at 70 psi. Pressure switch at boom point is set at 2500 psi. The system uses a 400 pound drum of MPG.

To Auto LubeBoom (19 Points) ......

11 II II

Hoist Float Sheaves (House Roof)

II II

ToAutolubeFairlead (20 Points)

...a ~)=~~~~~~~~~~~~~~~~~~ II

II To Air Piping

Air Pump System

Total Points Serviced- 59

SCHEMATIC AUTO LUBE - FRONT END

3-23

EM029421-0 (en-us)

Int. Boom Support Ropes

(

Boom Support Ropes

\

Boom Support Link Pin

Hoist Rope Deflector Sheaves Hoist Rope F Ioat Sheaves

'------ICD<L:J-- _ _ _ Connects Here to Auto Lube -Front End

SCHEMATIC AUTO LUBE- TAl-STRUCTURE

( 3-24

EM029421-0 (en-us)

CAUTION: This system contains a shut-off valve for isolating segments for maintenance. For system to supply bearings with proper lube, valves must be open during machine operation.

A Drag Sheaves Top

Swivel Journal Top

Swivel Thrust Top

Swivel Thrust Top

Shut-off Valve

Drag Sheave Bottom

Swivel Thrust Bottom

Swivel Journal Bottom

Swivel Journal Top

Drag Sheave Bottom

Connects Here to Front End

SCHEMATIC AUTO LUBE- FAIRLEAD

3-25

Swivel Journal Bottom

Swivel Thrust Bottom

EM029421-0 (en-us)

A

CAUTION: When lines to intermecHate boom support injectors are isolated by shut-off valves, lube cannot reach connections. Monitor these valves closely to avoid damage to parts.

~--

(

Boom Point Sheave Assy.

Pressure Switch Right Boom Sup. Ropes

Left Boom Sup. Ropes

Right Int. Sup. Rope Left Int. Sup. Rope

Shut-off Valve

'------III<!

Connects Here to Auto Lube - Front End

SCHEMATIC AUTO LUBE - BOOM

( 3-26

EM029421-0 (en-us)

LUBRICATION OF ROTATING GEAR CASE is accomplished by circulating the lubricant from bottom of case to top bearings and gear train with an electric motor and pump assembly.

There is a valve located in the return line between the case sump and the sediment separator.

Close this valve and clean the separator once a week.

nr \ !\\ l r----- m1

I

-~· ~

II

I

I

(I

'll~ -·~ __ _L __ -I

1

''

II

II I'

ll l'

: \

: 1

1

1 I

I I

l~ J- 1: I

1

I

I

------

1

:

I

1 Flow Monitor

for 1 Switch Alarm System

I I

Tell-Tale Filter

II

II

1 I

NOTE: Case drain also found at side of case near Intermediate Shaft.

Case Drain (1 of 2)

LUBE SYSTEM- ROTATING GEAR CASE A TELL-TALE FILTER is located in the output line from the oil pump assembly. This filter has a 149 micron metal mesh screen and magnetic plugs to remove ferrous contaminates. When filter is dirty, the pressure drop across the inlet and outlet parts will cause the pointer, located on the side of the filter body, to indicate that filter element needs cleaning.

To clean the filter, shut down the pump and close the valve in the outlet line from the case sump. Remove the end plate from the filter assembly and pull out the filter element. Wash the screen and magnetic plugs in approved solvents.

With a slight change in piping, the circulating pump assembly can be used to drain lubricant from the case for the seasonal change. After lubricant has been pumped out, open globe valve under the intermediate shaft lower bearing and remove the drain plug from under the lower main gear bearing. Both drains are accessible from inside the rotating frame.

3-27

EM029421-0 (en-us)

After draining case, clean and flush case with light oil. Close all valves, replace plugs and fill case with 280 gallons of type G L gear lubricant.

(

The HOIST, DRAG AND PROPEL GEAR CASES are also equipped with gear oil circulation pump systems and magnetic filters. The oil is pumped continuously from the bottom of the case, thru a separator and a filter, then returned to the case at the gear mesh. There is a valve in the return line between the case sump and the separator. Shut off pump, close the valve, and clean the seperator once a week.

A TELL-TALE FILTER is located in the output line from the oil pump assembly. This filter has a 149 micron metal mesh screen and magnetic plugs to remove ferrous contaminates.

When the filter is dirty, the pressure drop across the inlet and outlet ports will cause the pointer, located on the side of the filter body, to indicate that the filter element needs cleaning. To clean the filter, shut down the pump and close the valve in the outlet line from the case sump. Remove the end plate from the filter assembly and pull out the filter element. Wash the screen and magnetic plugs in petroleum solvent or kerosene.

Motor and Pump NOTE: Typical installation shown, three places on Hoist Gear Cases and two places on Drag Gear Case.

HOIST AND DRAG GEAR CASE LUBRICATION SYSTEM

( 3-28

EM029421-0 (en-us)

Motor and Pump Separator

NOTE: Typical installation, left hand and right hand Propel Gear Cases.

PROPEL GEAR CASE LUBRICATION SYSTEM

3-29

EM029421-0 (en-us)

(

STANDARD LUBRICATION INSTALLATION

\

TYPICAL PIPE MOUNTING

U-Bolt Angle

Min. 18"

I

1/8 Pipe

U-Bolt

DO NOT BURN

TYPICAL HOSE MOUNTING

Stud or 5/16 Bolt

~Hw ~JL:n,

\

\\

"'

Every 3 Feet or as Required

"'

For more than one Hose, clip one, secure others to it with Ty-Rap.

( 3-30

EM029421-0 (en-us)

ADJUSTING AND MOUNTING OF LINCOLN INJECTOR

Adjusting /

Nut

""'

0

A new injector should be preset for maximum discharge.

Maximum adjustment is set by loosening locknut and turning adjusting screw until daylight (space) appears between indicator pin and adjusting screw. Turn adjusting screw back down until it touches the indicator pin, then lock in place with the locknut.

0 To reduce discharge, start at maximum setting.

With locknut loosened, turn adjusting nut clockwise u nti I desired discharge is reached. Set locknut. DO NOT adjust more than six full turns (from maximum) of the adjusting screw. Check discharge for 3 to 4 lube cycles for operation of injector.

1/8

MINIMUM HOSE BEND RADIUS MPSD NO.

Min. Radius (R)

Hose R5-5

3-3/8

Hose R2-8

7

Hose R2-12

9-1/2

Hose R2-16

11

Hose

3-31

EM029421-0 (en-us)

(

ASSEMBLY OF HOSE FITTINGS

Hose Hose

Socket Socket

Swivel End

Grease

Step One

0

- Cut hose end square with fine tooth saw or cut-off wheel.

- DO NOT cut back outer cover of hose.

- Secure socket. Screw hose counterclockwise onto socket until hose bottoms.

Back off 1/4 turn.

Step Two - Liberally grease nipple threads and inside of hose.

Step Three- Screw nipple clockwise into socket and hose. socket.

Tighten until snug against

( 3-32

EM029421-0 (en-us)

SECTION 4 MECHANICAL ADJUSTMENTS INDEX Page Tub .................................................... 4-1 Center Journal ............................................ 4-2 Disassembly of Center Journal ................................ 4-3 Roller Circle .............................................. 4-4 Roller Rails .............................................. 4-5 Hook Shoes .............................................. 4-5 Propel Machinery .......................................... 4-6 Propel Gear Cases .......................................... 4-7 Propel Motor Extension Shaft Assembly ........................ 4-8 First Intermediate Propel Shaft Assembly ...................... 4-10 Second Intermediate Propel Shaft Assembly .................... 4-12 Disassembling Propel Gear Case .............................. 4-14 Assembling Gear Case ...................................... 4-15 Main Propel Drive Pinion Shaft .............................. 4-16 Main Propel Shaft ......................................... 4-17 Walking Shoe ............................................ 4-18 Walking Shoe Rollers ...................................... 4-20 Walking Shoe Return Mechanism ............................. 4-21

EM029421-0 (en-us)

Section 4- Mechanical Adjustments (cont.)

Page

(

Machine Rotation ......................................... 4-21 Motor Extension Shaft ..................................... 4-21 Intermediate Shaft Assembly ................................ 4-22 Main Rotating Shaft ....................................... 4-22 Main Rotating Shaft Removal ............................... 4-24 Reinstalling Main Rotating Shaft ............................. 4-24 Main Drive Gear Assembly .................................. 4-30 Main Gear Bearings ........................................ 4-30 Main Gear Assembly Oil Seal ................................ 4-31 Drag Machinery .......................................... 4-32 Drag Drum .............................................. 4-32 Drag Intermediate Shaft Assembly ............................ 4-35 Hoist Machinery .......................................... 4-41 Hoist Drum ............................................. 4-41 Hoist Intermediate Shaft Assemblies .......................... 4-42 Disassembling Hoist Gear Cases .............................. 4-42 Hoist, Drag, Swing and Propel Brakes .......................... 4-46 Operation ...............................................

Mounting .........................................

Brake Adjustment ..................................

Inspection of Friction Disc ............................

Replacement of Friction Discs on Dual Disc Brake (Hoist, Drag and Propel) ...........................

Replacement of Springs ..............................

4-46 4-46 4-49 4-51 4-52 4-53

(

EM029421-0 (en-us)

Section 4- Mechanical Adjustments (cont.)

Page

Operation (cont.): Replacement of Diaphragm ........................... 4-54 System Static Adjustment Procedure .................... 4-55 Hoist and Drag Ropes ...................................... 4-56 Rope Winches ............................................ 4-57 Changing Hoist Rope(s) .................................... 4-57 Changing Drag Rope(s) ..................................... 4-58 Method of Lowering Boom ................................. 4-58 Method of Raising Boom ................................... 4-61 Boom Point Sheave Assembly ............................... 4-63 Disassembly of B'oom Point Sheaves ........................... 4-63 Point Sheave Bearing Assembly Procedure ...................... 4-66 Reassembly of Boom Point Sheave Assembly .................... 4-66 Boom Support Bridge Strands ............................... 4-67 Vibration Damper ........................................ 4-68 Adjustment of Intermediate Boom Support Ropes ............... 4-69 Tri-Structure Assembly .................................... 4-70 Hoist Rope Deflecting Sheaves ............................... 4-70 Replacing Deflecting Sheave Bearings .......................... 4-72 Safety Ropes ............................................ 4-74 Fairlead Assembly ........................................ 4-75 Fairlead Snubbers ......................................... 4-75

EM029421-0 (en-us)

Section 4- Mechanical Adjustments (cont.)

Page

Drag Rope Lower Sheaves .................................. 4-77 Replacing Lower Sheave Bearings ............................. 4-78 Drag Rope Upper Sheaves .................................. 4-79 Replacing Upper Sheave Bearings ............................. 4-80

( \'

EM029421-0 (en-us)

Propel Motor No.2

Left Walking Arm

Right Walking

0 0 0

Arm

Hoist Motors (5)

DECK PLAN

EM029421-0 (en-us)

PRINCIPAL WEIGHTS

(

Propel Machinery Weights: Lbs. Motor Extension Shaft ............................... 1215 1st Intermediate Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5575 2nd Intermediate Shaft ............................. 17200 1st Intermediate Gear ................................ 3504 2nd Intermediate Gear .............................. 10263 Main Propel Shaft .................................. 32530 Main Drive Gear ................................... 53066 Walking Arm ..................................... 79100 Walking Eccentric .................................. 46000 Propel Gear Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12530 Eccentric Bushing ................................... 6420 Eccentric Split Collar ................................ 1672 Eccentric Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 860 Stabilizer Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11230 Lateral Ball Joint Shaft .............................. 8897 Walking Shoe Knuckle ............................... 4060 Walking Shoe .................................... 181530 Rotating Machinery Weights: Gear Case Assembly ................................ 39398 Case Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10290 Case Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11077 Main Rotating Gear ................................ 11737 Intermediate Gear .................................. 1996 Motor Extension Shaft ................................ 395 Intermediate Shaft .................................. 1683 Main Rotating Shaft ................................ 13270 Main Shaft Pinion ................................... 2279 Main Shaft Bearing ................................... 605 Hoist/Drag Machinery Weights: Drag Drum Assembly (Less Gear) ...................... 99580 Drag Motor ....................................... 19500 Drag Motor Brake ................................... 1475 Drag Drum Lagging (Each Section) .................... 26880 Drag Drum End (Gear End) .......................... 24537 Drag Drum End (Opposite Gear End) .................... 9770 Drag Drum Gear ................................... 29924 Drag Drum Bearing Housing ........................... 3474

( \

EM029421-0 (en-us)

Principal Weights (cont.)

Lbs.

Hoist/Drag Machinery Weights (cont.): Drag Drum Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544 Hoist Drum Assembly (Less Gears) ................... 113520 Hoist Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19500 Hoist Motor Brake .................................. 1475 Hoist Drum Lagging ................................ 26880 Hoist Drum End ................................... 24537 Hoist Drum Gear .................................. 29924 Hoist Drum Bearing Housing .......................... 3774 Hoist Drum Bearing .................................. 544 Hoist/Drag Intermediate Shaft Assembly ................ 25324 Hoist Gear Case (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105000 Hoist Gear Case (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63290 Boom Point Sheave Assembly Weights: Shaft ............................................ 3960 Sheave .......................................... 11610 Bearing ............................................ 300 Trunnion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10930 F rant Bearing Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 Rear Bearing Block .................................. 4440 Trunnion Assembly ................................ 47280 Fairlead Assembly Weights: Upper Sheave ..................................... 14310 Lower Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10460 Swivel Frame ..................................... 21680 Upper Swivel Shaft ................................... 476 Lower Swivel Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066

EM029421-0 (en-us)

(

EM029421-0 (en-us)

SECTION 4 MECHANICAL ADJUSTMENTS

The TUB or base structure requires little maintenance. Manholes in top plate and bulkheads provides access for inspection. Check this structure at regular intervals for cracks, broken welds, deformed bottom plates or bulkheads caused by working over rocks or uneven ground. Note particularly any bent or damaged plates in roller circle area, rotating gear or center journal. Look for the effect on flatness or alignment of components. Repair ALL damage promptly. Keep tub area clean and DRY.

Roller Circle Rail

Center Journal

Rotating Gear

Hook Shoe Rail

Wear Plates

TUB BASE FRAME ASSEMBL V

4-1

EM029421-0 (en-us)

CENTER JOURNAL pin holds the rotating frame and the tub in concentric alignment at the center of rotation.

DANGER:

(

Remove power from machine prior to removing housing from collector rings or gaining access to rings area.

Upper Frame

'

'

i ~· ~Center Journal (Tub)

i Center Journal Pin (5731 lbs.)

Lock Bar (371bs.)

1

Retainer

:

~j ::l

I r.,

Guard (103 lbs.)

'

! --

~

1775 Rotoloec

--~

--~-~oc'k Bar (37 lbs.)

i (~~~k:s.)

F===

lb•.l

g,.,J;;==:;t,,...,..,~.HI--N

1 I

~

The pin is assembled into a heavy CENTER JOURNAL welded to the tub structure. Two lock bars secure the pin. The upper frame Bearing Spacer (1652 lbs.) (413 lbs.) rotates around the pin on a large diameter Detail A spherical roller bearing. The bearing cone (inner race) is clamped between a spacer and a bearing retainer which is bolted to the top of the center journal pin. The bearing cup (outer race) is mounted in a retainer assembly which moves vertically on four aligning pins. These pins also prevent rotation of the retainer assembly.

L::----'----+'

It is not necessary to disconnect incoming electrical power to service or inspect the center journal bearing because the collector rings are isolated. It will be necessary to disconnect and remove the collector rings if bearing replacement is required.

( 4-2

EM029421-0 (en-us)

DISASSEMBLY OF THE CENTER JOURNAL in the field is not usually performed, however it can be accomplished if necessary. Park the machine on level ground and, with the bucket still suspended, crib firmly under the ballast section of the upper frame. Now, tie the upper and lower frames together with at least three sets of X bracing on each side to prevent tilting between the two frames.

Next, set the bucket on the ground but keep tension on the hoist ropes.

Take electric power off the machine, disconnect the trail cable and bring it into the machinery house and up to the high voltage cabinet. Disconnect the leads from the collector rings and connect the trail cable in their place. This will provide power to the lights and overhead cranes but not to the collector rings.

Remove a section of the drag rope dirt chute above the center journal to provide access for the overhead crane lines.

Remove the floor covering from above the center journal, then disconnect and remove the collector ring assembly.

A

DANGER: Be sure power is off rings and locked out before working on rings.

Remove the guard and top bearing retainers, then remove the bearing from the upper frame bore.

Remove the lock bars from the lower end of the center journal. Use a jack and overhead cranes to remove the center journal pin from the tub base. If removal of the center journal pin has to be done in an area of blasting, arrange for "no blasting" until the pin has been replaced.

NOTE:

The center journal pin has provisions for hydraulic assisted removal from the tub

bore. There is a hole stamped "HR"on top of pin for connecting hydraulic line from pump.

To remove center journal bushing, remove bearing and bearing retainers, then remove four brass dowel pins which secure bushing in the upper frame bore.

Reverse this procedure to reassemble the center journal. Be sure to fill bearing cavity with MPG multi-purpose grease before installation of the bearing.

4-3

EM029421-0 (en-us)

The ROLLER CIRCLE contains 143 tapered steel rollers. The rollers are held in place by retainers, splice bars and a thrust rail.

n

n

I

~~·

..----~JY-~~..__._1

[ __ _j

I

1

I

I

I

(

--:

. . . . . _ _ i-

=t

,----

1

1-- Upper Rail -t (1640 lbs.)

Apply Molycote to : Thrust Rail and Roller Surfaces

Thrust Rail Segment (160 lbs.)

Bracket Section (129 lbs.)

Apply Molycote (Typical Both Sides) rf1111n'I'Titr~:....;o.~:t_-- Torque to

645 ft.-lbs.

(Four Places) Retainer (191bs.)

._.,,'-'A--

Outer Splice Bar (42 lbs.)

Outer Retainer (192 lbs.)

1

Inner Retainer (183 lbs.)

Roller

r--------~---(3_8_3-lb_s_.)

Inner Splice Bar (40 lbs.)

Lower Rail (1550 lbs.)

__

I

I

-r I I

I

w I

CROSS SECTION THRU ROLLER ASSEMBLY- TYPICAL 36 PLACES To prevent damage to rails or other rollers, immediately remove a roller from the circle if it becomes chipped, broken or damaged in any way. Remove the roller by rotating the machine until damaged roller is directly below roller removal hole in rotating frame. Remove four capscrews which attach retainers to rollers. Use suitable tongs or sling to lift roller

( 4-4

EM029421-0 (en-us)

from circle. Replacement roller diameter must not exceed diameter of adjacent rollers.

Match to +/-.002 measured at large end radius. Apply .001 thick coating of Molycote to surfaces indicated in roller figures. Lower new roller into place and install retainers with capscrews. Make sure large end of roller is toward outside of circle.

Apply Molycote Retainer (15 lbs.)

Retainer (15 lbs.)

Torque to 645 ft.-lbs.

(Four Places)

Inner Retainer (183 lbs.)

Outer Retainer (192 lbs.)

Roller (383 lbs.)

CROSS SECTION THRU ROLLER ASSEMBLY- TYPICAL 107 PLACES

Both ROLLER RAILS have been accurately aligned concentric with the center journal on a machined surface. The tub rail forms a circle bolted in place thru the rail flange. A similar rail is bolted to the bottom of the rotating frame. This rail has two open spaces to allow for removal of rollers. In addition, thrust rail segments are bolted to the outer flange and bracket sections are bolted to the inner flange. Lubrication of the roller rails is accomplished by automatically dripping on open gear lubricant at two diametrically opposite points.

Two HOOK SHOES lift the leading edge of the tub during the walking step. Each hook shoe is pinned to a support casting that is welded into the bottom of the rotating frame.

There should be .38 inch running clearance between the hook rail on the tub and the wear plate on the hook shoe. Use shims and plates as required to maintain this clearance.

The hook shoe may be disengaged by removing the rear pin, swinging hook toward rear of machine and replacing pin in top hole to hold shoe.

4-5

EM029421-0 (en-us)

(

.38

y

,,

I

1\ I

Use Shims and Plates as required to achieve .38 running clearance

I ,1

Hook Shoe (6312 lbs.)

'

I

/ / ;'

/

HOOK SHOE

The PROPEL MACHINERY consists of two separate assemblies, one on each side of machine. Each unit operates independently except for an electrical connection that synchronizes the walking step.

First Intermediate Shaft (5575 lbs.)

Motor Extension Shaft (12151bs.)

Second Intermediate Shaft ( 17200 lbs.)

Main Drive Gear (53066 lbs.)

Propel Motor Main Drive Pinion Shaft (6076 lbs.)

Propel Drive Shaft (32530 lbs.)

Walking Shoe (181530 lbs.)

The walking shoe is actuated by an eccentric cam that is driven by an electric motor thru a three gear reduction.

( 4-6

EM029421-0 (en-us)

PROPEL GEAR CASES are oil tight and enclose first three shaft assemblies of propel gear

train. These shaft assemblies are propel motor extension shaft, first intermediate propel shaft and second intermediate propel shaft.

Oil Drain is under Case, inside Rotating Frame

Second Intermediate Propel Shaft

NOTE: Gear Case capacity is 300 U.S. gallons.

PROPEL GEAR CASE

4-7

EM029421-0 (en-us)

(

PROPEL MOTOR EXTENSION SHAFT ASSEMBLY is coupled directly to propel motor armature shaft. Extension shaft is mounted on bearings with eccentric housings which are used for gear alignment. An integral pinion drives large diameter helical gear of first intermediate propel shaft assembly.

Grid Type Coupling, See Engineering Data Section 7

8

~,>-:::-...,( ~~~ 11

~12

""" 13

1 2 3 4 5 6

Gear Case Retainer Shims Bearing Pin Bearing Housing (Eccentric)

7 Extension Shaft

8 Retainer 9 Split Seal 10 Fitting, Button Head 11 Retainer 12 Bar 13 Coupling

PROPEL MOTOR EXTENSION SHAFT ASSEMBLY

( 4-8

EM029421-0 (en-us)

BEARING SET-UP PROCEDURE: Take up on cup follower until bearings bind slightly in rotation. Install sufficient shims to give .003 to .005 preload. Wire lock retainer.

NOTE: Wire lock cap screws in eccentric bearing housings in pairs.

First Intermediate Propel Gear (35041bs.)

Coupling See Engineering Data Section 7 Retainer (70 lbs.)

Bearing Housing (Eccentric) (132 lbs.)

Manual Lube Point

Bearing Housing (Eccentric) (132 lbs.)

Bearing (83 lbs.)

Pack cavity between Seal and Retainer with Belray Silicone Valve Seal Lubricant (MPSD No. 179639-9).

Use Grease Gun to Replenish as required thru lube fittings in Retainer.

At Assembly, coat O.D. of Shaft in Seal area with Belray Silicone Valve Seal Lubricant.

NOTE: Correct position of Eccentric Bearing Housings is set at time of manufacture and fixed by installation of a Dowel Pin.

PROPEL MOTOR EXTENSION SHAFT ASSEMBLY

4-9

Gear Case

EM029421-0 (en-us)

FIRST INTERMEDIATE PROPEL SHAFT ASSEMBLY is a large diameter helical gear splined to a shaft with an integral pinion which drives second intermediate shaft assembly.

Shaft bearings are not mounted in eccentric housings in this assembly.

1 2 3 4 5

Gear Case Bearing Retainer Retainer Spacer

6 7 8 9 10

/

\

Gear Propel Shaft Shim Shim Retainer

FIRST INTERMEDIATE PROPEL SHAFT ASSEMBLY

( 4-10

EM029421-0 (en-us)

.

Second Intermed1ate Prooel Gear '-..

(102631bs.) "'-

-

-

,.-

First ntermediate . - - ....,_ Direction of Teeth Propel Gear ....,L_ ~ >(~N S"d ) -,~'-.. "-."-.~ ear I e (35041bs.)

,........._._..[7

1/

l7 '-

v

v I/

l/

~ ~"-,.

ILr--- V

,..._

II

~""""""

v

~

II

v

II /

0

V

/

Shims

1.- Wire Lock Cap Screws Together

0

NOTE: For Disassembly and Assembly of Involute Splined Gear and Shaft, See Engineering Data Section 7.

II II II II II

~

II 1.1 II

BEARING SET-UP PROCEDURE: Take up on cup follower until bearings bind slightly in rotation. Install sufficient shims to give .004 to .008 preload.

FIRST INTERMEDIATE PROPEL SHAFT ASSEMBLY

4-11

EM029421-0 (en-us)

SECOND INTERMEDIATE PROPEL SHAFT ASSEMBLY is a large diameter helical gear splined to propel shaft which is coupled to main propel drive pinion. Shaft assembly is mounted on bearings with eccentric housings which are used for gear alignment.

(

8

/

1 2 3 4 5 6 7 8

Gear Case Bearing Shim Shim Shim Retainer End Plate Pin

II'~

9 Bearing Housing (Eccentric) 10 Retainer 11 Gear 12 Shaft 13 Retainer 14 Seal 15 Retainer

SECOND INTERMEDIATE PROPEL SHAFT

( 4-12

EM029421-0 (en-us)

Second Intermediate Propel Gear ( 1 0263 lbs.)

Direction of Teeth (Near Side)

NOTE: For Disassembly and Assembly of Involute Splined Gear and Shaft, See Engineering Data Section 7.

NOTE: Wire lock cap screws in eccentric bearing housings and shaft end plate in pairs.

Bearing Housing (Eccentric) (4951bs.)

Lip Seal Shaft

Retainer (2531bs.)

Retainer

Spray Shaft with Molycote M-3402 in Lip Seal area. Pack Seal Cavities with Belray Silicone Valve Seal Lubricant Before Installing Seal.

NOTE: Correct position of Eccentric Bearing Housings is set at time of manufacture and fixed by installation of a Dowel Pin.

Bearing Housing (Eccentric) (4951bs.)

BEARING SET-UP PROCEDURE: Take up on cup follower until bearings bind slightly in rotation. Install sufficient shims to give .003 to .005 preload.

SECOND INTERMEDIATE PROPEL SHAFT ASSEMBLY

4-13

EM029421-0 (en-us)

Before DISASSEMBLING PROPEL GEAR CASE clean case, cover, splined coupling and motor coupling of all dirt, dust, or grit.

(

First disengage splined coupling from main propel pinion shaft. This is done by removing outboard split retainer ring and sliding splined coupling toward gear case.

I

r da

I-.

]

D.-,

J 6j----- ~"

-

Second lntermediateShaft (17200 lbs.)

1

~~

~

Coupling

I

+

-

t ---""' "'" "' I

!)(

L1

p

v

Main Propel Pinion Shaft

TI

Split Retainer Rings (381bs.)

r

.-First Intermediate Shaft (5575 lbs.)

--

"'! t-

~FX' !'-"

--

+

"~ l;J

II Motor Extension) 1 Shaft (12151bs.

j_

/

I

1

I:8J

r---, ___

~ IX

~ 1---

f

~

f-.

t I

~

l1fl

;p

-Lllf-

Coupling Half

l

PLAN VIEW OF PROPEL CASE

(4-14

EM029421-0 (en-us)

Next, separate the motor coupling halves and remove cap screws from top half of all bearing plates, eccentrics and flanged sleeves. Loosen bottom cap screws about two turns.

Remove gear case cover. It may be necessary to drive a small wedge between case and cover to break seal. Lift off cover using lifting holes provided.

A

CAUTION: Gear case cover weighs 5930 lbs.

Remove bearing retainer plates and shims, wire shims to retainers to prevent loss. Remove cap screws from bottom of bearing housing. Starting with motor extension shaft, then first and then second intermediate shafts. Carefully lift shaft assemblies from gear case. Drain and flush out case with light oil, clean thoroughly.

If the same parts reassemble, use the same shims, BUT if any parts are replaced, always use new shims.

ASSEMBLE GEAR CASE by lowering second intermediate shaft in place first, then proceed to high speed shaft. Coat outside of bearing housing with Permatex that has contact with case. Be sure bearings are well seated in housing.

Carefully align gear faces. See Eccentric Cartridge in Engineering Data, Section 7.

Apply Permatex (MPSD Part No. 134562-1) to top of case, 1/64 inch thick. Lower cover in place, install rod bolts, and hold down bolts. Lubricate and tighten rod bolts to 4380 foot-pounds. Also, lubricate and tighten hold down bolts to 1100 foot-pounds. Bolt eccentric bearing housings to gear case. Torque and lockwire cap screws.

Adjust anti-friction bearings next. The bearing preload is determined by placing shims between bearing retainer cap and bearing housing on one end only. Draw down retainer cap WITHOUT shims, turning cap screws progressively until bearing binds slightly when rotated.

Measure, 120 degrees apart, gap between cap and housing at three places. Average the three measurements and install shim(s) of this dimension minus 0.003 to 0.005 inch for motor extension and second shaft preload, and .004 to .008 inch for first shaft preload. Be sure to coat both sides of shim material with Permatex before installing. One shim is laminated (0.002 to 0.003 increments), and can be made to correct thickness by removing laminations.

Reassemble bearing retainer with proper shim(s) and tighten cap screws, one end only, to proper footpound (See Section 7).

Replacement oil seal on input and output shafts are split seals. Spray lip seal area of shaft

4-15

EM029421-0 (en-us)

(

with Molycote M-3402 (MPSD No. 170025-1) and pack seal cavities with Bel ray Silicone Valve Seal Lubricant (MPSD No. 179639-9). Install as shown in Engineering Data Section with lip seal TOWARD case.

I\

Add 300 U.S. gallons, or to dipstick full mark, of G L lube in gear case (see Lube Section).

MAIN PROPEL DRIVE PINION SHAFT is coupled to second intermediate propel shaft and drives main propel shaft.

Bearing Housing (1477 lbs.)

Pinion Shaft (60761bs.)

Bearing Housing (1316 lbs.)

Torque to 905 ft.lbs.

Seal Nut Retainer (1151bs.)

Retainer (681bs.)

Assembly notes: 1. Coat coupling splines with type "B" OGL at assembly.

2. Bearing adjustment - tighten caps (retainers) at each end of shaft and measure gap between cap and housing (three places minimum) and average the measurement. Shim caps to this measurement. Rotate bearing while clamping up tightly thru cones to assure proper seating of rollers.

3. Grease bearings with multi-purpose grease at assembly.

4. Single-row bearing must be assembled on shaft with bearing housing in place at coupling end of shaft. Tighten special nut until inner race of bearing is secured in place. Lock nut onto shaft with cap screws.

5. Spray coat shaft in lip seal area with Molycote M-3402 (MPSD No. 170025-1 ).

6. After assembling bearings, measure gap under retainer and add shims, leaving .010 for clamping.

( 4-16

EM029421-0 (en-us)

MAIN PROPEL SHAFT assembly consists of main drive gear, propel shaft and walking eccentric. Gear hub and walking eccentric are splined to shaft with involute splines. Shaft is supported by two large diameter bronze bushings. Propel shaft is inserted thru assembly from outside after gear hub and eccentric have been blocked in place. Shaft is locked in place with two split collars.

Walking Arm (79100 lbs.)

Bushing---(6420 lbs.)

Drive Gear (53066 lbs.)

Eccentric----....1 (46000 lbs.)

Split Collar (564 lbs.)

Split Collar (286 lbs.)

Shaft (32530 lbs.)

Gear Hub (12530 lbs.)

1-C::t:l:t-- Drive Fit Bolts

See Section 7 for Assembly

Bearing (1188 lbs.)

Spherical Shoe Connection

Thrust Washer (1751bs.)

Coat shaft, bushings, eccentric splines and gear hub splines with Molycote M-8800 (MPSD No. 109569-2) at assembly. After assembly, fill cavities at eccentric splines and gear hub splines with OGL Type "B" grease.

4-17

EM029421-0 (en-us)

The following views show the relationship of the split propel drive gear to the eccentric assembly:

(

Eccentric in Park Position

VIEW FROM LEFT SIDE OF MACHINE

VIEW FROM RIGHT SIDE OF MACHINE

WALKING SHOE is a one piece weldment. Manholes in the top plates and bulkheads are provided for shoe inspection.

Shoe attaches to walking arm by a swivel and spherical knuckle assembly. Spherical knuckle allows shoe to rotate about longitudinal axis. Swivel shaft will also slide within knuckle to allow lateral shoe movement.

( 4-18

EM029421-0 (en-us)

Stabilizer Arm (11230 lbs.)

Shoe (181530 lbs.)

0

~

~~~~~~l.___.v L.H. Shoe Assembly as Shown R.H. Shoe Assembly is Opposite Hand

_] Thrust Washer (74 lbs.)

Shaft---(88971bs.)

Retainer (306 lbs.)

Walking Arm Bushing Half (12151bs.)

PROPEL LINKAGE AND SHOE ASSEMBLY

4-19

EM029421-0 (en-us)

WALKING SHOE ROLLERS are mounted on the rotating frame at two places above each shoe assembly. These rollers keep shoes aligned parallel to the rotating frame when the shoes are in the park position. The rollers also keep shoes from flopping when the swing motion is slowed or stopped by "plugging".

(

Rotating Frame

0 A Roller (4551bs.)

Shoe

Roller (455 lbs.)

Centerline Shoe

T-Head Pin Heat & Bend

Rotating Frame

Centerline Machine

42'-0"---l

I

Shoe 3-1 /2" interference with machine on level ground.

(High point of cycle)

Manual Lube Weekly with multi-purpose grease

50"

A-A ROLLER AND SHAFT ASSEMBLY

( 4-20

EM029421-0 (en-us)

WALKING SHOE RETURN MECHANISM returns the shoes parallel to the rotating frame after shoe is returned to the park position. This is done by two spring loaded wire ropes at each shoe. The spring case is welded to the underside of the rotating frame. The ropes reeve thru a sheave also on bottom of rotating frame and then are attached to an adjustable U-bolt anchor on walking shoe.

Adjust return by turning the clevis nut on return spring rod against spring case end plate until rod is extended 1 foot 9 inches. Run nuts to end on the walking shoe anchor U-bolts to make available 4 inches of adjustment.

Manual Lube

Clevis Nut

Wire Rope Manual Lube

Spring

Wire Rope Clip Deflector Sheave

Reeve wire rope as shown in sketch. Pull rope as tight as possible and secure each end with five rope clips. Remove all rope slack by turning nuts on U-bolts. Turn nut on spring rod and lock against clevis. If shoe does not consistently return parallel to rotating frame, adjust U-bolt accordingly.

MACHINE ROTATION is powered by five vertical mill type electric motors. Each motor mounts on a double reduction gear case. All cases are the same and spaced across the front of rotating frame.

Each case consists of three shaft assemblies: The motor extension shaft, the first intermediate shaft and the main rotating shaft assembly. All shaft assemblies mount on anti-friction bearings in the oil tight case.

MOTOR EXTENSION SHAFT with an integral helical pinion, is directly coupled to the motor armature shaft by a flexible coupler.

The extension shaft mounts in the motor base casting. The top of shaft is supported by a tapered double row roller bearing and the bottom by a cylindrical roller bearing. Both

4-21

EM029421-0 (en-us)

bearings are seated in eccentric housings. Permatex (MPSD Part No. 134562-1) is applied to the outer surface of the housings. Assemble the shaft, with bearings, in housing. Draw top bearing retainer up tight to provide clamp of 0.005 inch maximum on bearing. Draw bottom up then add shims to give 0.002 to 0.004 inch clearance between retainer and bearing. Apply Permatex to both sides of shims.

(

INTERMEDIATE SHAFT ASSEMBLY is mounted in the case on two double row, tapered roller bearings that are also seated in eccentric housings. A large helical gear is assembled on top of the integral pinion shaft by means of involute splines. The gear is held in place by a bearing nut and locked with four pinch bolts. The pinch bolts are lock wired in pairs. Draw top bearing retainer up until top and bottom bearings bind slightly while rotating shaft. Add shims under retainer to give 0.030 to 0.040 inch clearance between bearing and retainer.

MAIN ROTATING SHAFT, supported by self aligning spherical roller bearing, extends from the main rotating gear thru rotating frame to the rotating pinion below frame. A bearing retaining spacer with labyrinth grease seal is assembled on each side of the spherical bearings.

The main rotating shaft is attached to drive gear by means of crowned external involute splines, that mate with regular involute internal splines in gear hub. The crowned splines will permit a limited deflection between gear and shaft.

The crowned splines and self aligning spherical bearing compensate for initial and dynamic deflection of the rotating shaft caused by start, stop and sudden reversals of shaft. For the same reason the teeth of rotating pinion are crown cut also.

The main rotating shaft can be removed without disassembling the gear cover or draining lubricant from case. See Figure titled "Rotating Shaft Removal".

Swing rotating frame so that shaft to be removed is over access hole in top plate of tub.

Remove cover plate from gear case. Insert lifting eye in threaded hole in top of shaft.

Attach overhead crane to eye and snug up just enough to support shaft weight. Remove lock plate and drop off pinion. Remove lip seal from bottom of main drive gear. This split seal can be reached from inside upper frame weldment. lift shaft straight up, pulling it from spherical bearing. Pull shaft out far enough to install lifting fixture, then lift clear of case.

Remove spherical bearing by removing lock bars and lifting sleeve from boss.

( 4-22

EM029421-0 (en-us)

Grid Coupling Lube Plugs in Cover, See Section 7

Manual Lube at 500 Hours with MPG Main Drive Gear (117871bs.)

Motor Extension Shaft (395 lbs.)

·------

Gear Case Capacity is 280 U.S. gal. of GL oil

ROTATING MACHINERY

4-23

EM029421-0 (en-us)

(

MAIN ROTATING SHAFT REMOVAL

484107-7 Lifting Fixture from Machine Tools and Supplies

NOTE: Shaft Weight is 13,270 lbs.

I

C Machine

1. Check to ensure that hoists are assembled on rails so that lifting hooks will be as close together as possible.

2. Remove pinion assembly from bottom of shaft.

A 3.

4.

5.

6.

7.

DANGER:

Bottom bearing spacer is free to drop out of sleeve as pinion is removed.

Remove lip seal from bottom of main drive gear.

Remove round cover over shaft on top of gear case.

Use 1-3/4" threaded lifting eye to pull shaft out far enough to install lifting fixture.

Let shaft and fixture rest on case and hook hoists to each side of fixture.

Lift shaft clear of gear case.

REINSTALL MAIN ROTATING SHAFT as shown in Figure titled "Main Rotating Shaft Assembly". Install lip seal in accordance with Engineering Data Section 7. Be sure to spray shaft with Belray silicone valve seal lubricant in lip seal area. Reinstall pinion and retainer.

Shim to maximum .015 gap between shims and end of rotating shaft.

( 4-24

EM029421-0 (en-us)

Gear Case Assembly (39398 lbs.)

Fill to Oil Level Plug in side of Case

D

Apply MPG to Splines and Thrust Washer

Torque Cap Screws to 3565 ft-lbs.

Main Shaft (13270 lbs.)

Bearing Shield (221bs.)

Spray Shaft in Lip Seal area with Bel ray Silicone Valve Seal Lubricant (MPSD No. 179639-9) Bearing Spacer (1781bs.)

A-A .015 Gap Max. Between Shims and Shaft

MAIN ROTATING SHAFT ASSEMBLY

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EM029421-0 (en-us)

(

@ Detail

Parts of Grid Coupling See Engineering Data Section 7 for Assembly/Disassembly.

-~

Shim

Retainer Bearing

ROTATING GEAR CASE ASSEMBLY

( 4-26

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Case Cover (10290 lbs.)

Main Gear

Spacer

ROTATING GEAR CASE ASSEMBLY

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EM029421-0 (en-us)

(

Coupling (See Engineering Data Section 7) TOP BEARING SET-UP: Draw up retainer. Measure gap at eccentric.

Shim gap at retainer and eccentric to provide clamp of .005 max. on bearing.

e.ll---- (Remove Lube Points in Cover Plugs) Nut

Spacer (58 lbs.)

Split Retainer for Oil Seal (51bs.)

Oil Supply

Apply Permatex

Bearing Housing (Eccentric) Top (78 lbs.)

Bottom (52 lbs.)

Intermediate Gear

Wire Lock in Pairs BOTTOM BEARING SET-UP: Draw up retainer. Measure gap at eccentric, then add shims to give .002 to .004 clearance between retainer and bearing.

MOTOR EXTENSION SHAFT ASSEMBLY

( 4-28

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Wire Lock Screws in Pairs

Bearing Housing (Eccentric) (1221bs.)

Tighten special nut against gear.

Tighten capscrews and wire lock in pairs.

Intermediate Gear (19961bs.)

Apply Locktite No. 242 at Assembly

BEARING SET-UP PROCEDURE: With main rotating shaft removed, draw up top bearing retainer until both bearings bind slightly while rotating shaft. Add shims to give .030 to .040 clearance between bearing and retainer.

Intermediate Shaft (16831bs.)

Oil Level

r-----

Bearing Housing (Eccentric) (263 lbs.)

Apply Locktite No. 79 to Threads

Spacer (69 lbs.)

Bearing (157 lbs.)

Retainer (181bs.)

Wire Lock Screws in Pairs

~-----t- Apply Locktite

No. 242 to Threads Oil Drain Valve' (1 of 2)

VIEW A INTERMEDIATE SHAFT ASSEMBLY

4-29

EM029421-0 (en-us)

MAIN DRIVE GEAR ASSEMBLY consists of a gear which rotates on two single row bearings. The main rotating shaft is splined to the drive gear in the center of the gear hub.

( \

The MAIN GEAR BEARINGS are set up as follows with main shaft removed: Complete assembly of bearings in case, then draw up top bearing retainer by torquing four equally spaced bolts to 90 ft. lbs. Turn gear as bolts are tightened to insure even loading.

Measure gap between retainer and boss near each of four bolts. Take average dimension to determine shims required and install shims. Install and torque all retainer bolts. Wire lock bolts securely. After main rotating shaft is assembled in case, recheck for required gap between retainer and boss. .... ......

Oil Level

\..L44N.I---

Bearing (270 lbs.)

Wire Lock in Pairs

Retainer (132 lbs.)

Check for Clearance Between Retainer and Gear Hub when tightening Cap Screws. MUST NOT TOUCH.

( 4-30

EM029421-0 (en-us)

MAIN GEAR ASSEMBLY OIL SEAL is installed as follows: A. Inspect surface of gear hub area. Surface must be free of scratches or defects.

B. Coat surface with a silicone grease (valve seal lubricant- MPSD No. 179639-9) or equal.

C. Insert rings one at a time. Seat with wood block. Be sure ends are matches- no gaps or overlaps permitted. Splits to be spaced 120 degrees apart.

D. Initial compression to be .1 00/.160 - as seal wears, remove shims and store under cap screw head on outside of retainer. This prevents bottoming of cap screw.

E. When all adjustment is used (no shims remain under retainer), remove retainer and add one new ring to cavity. Replace shims under retainer and adjust shim to height as required.

NOTES:

4-31

EM029421-0 (en-us)

DRAG MACHINERY consists of a drum driven by four mill type D.C. motors thru a double reduction gear train of four motor extension shafts and two intermediate shafts. The first reduction is mounted in an oil-tight gear case.

(

Motor and Brake (Typical) Motor ( 19500 lbs.)

Brake (1475 lbs.)

Pedestal

DRAG DRUM is an assembly of two rope lagging sections bolted together at the center with rod bolts. The drum end castings and gear hubs are rod bolted to the lagging. The split double helical drive gear halves are joined together and mounted on the drum end.

NOTE: All drive gear bolts should be checked after the first week of operation and every 500 hours thereafter. If any bolts are loose, repeat the tightening procedure.

( 4-32

EM029421-0 (en-us)

Rope Clamps Drum End (9770 lbs.)

Lagging (26880 lbs.)

Lagging (23080 lbs.)

Drum End (24537 lbs.)

Bearing Housing (3474 lbs.)

Retainer (158 lbs.)

Tension Rods to 246,260 lbs. or Torque to 12,315 ft-lbs.

Tension Rods to 165,000 lbs. or Torque to 6875 ft-lbs.

Auto Lube Point

Auto Lube Point

I

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I

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1 I

1 I

NOTE: Cap Screws in Retainers at each end of Drum Shaft to be Wire Locked in Pairs.

Weight of Assembly is 99,580 lbs.

Use Witness Holes for alignment of Drums and Drum Ends.

DRAG DRUM SHAFT ASSEMBLY (Viewed from rear of Machine) TIGHTENING NOTE FOR DRAG DRUM RODS: Use hydraulic tensioner (bolt stretcher) to apply a clampload in 3.00 inch dia. finished rods of 246,260 lbs. If tensioner cannot be used, torque to 12,315 ft-lbs. Tension 2.50 inch dia. finished rods to 165,000 lbs. or torque to 6875 ft-lbs.

DRUM SHAFT ASSEMBLY INSTRUCTIONS:

1. All finished drum end surfaces should be free of metal chips and surface obstructions.

Clean all finished drum end surfaces with an approved solvent without an oil base and wipe dry before assembly.

2. Install bearings and housings on drum ends; ensure that correct housing is used on correct drum end. Assemble housings with cast note "outside" facing away from drum.

3. Install drum ends on drum barrels using witness holes for alignment of drums and drum ends.

4. Using hydraulic tensioner, tighten rod bolts at top of drum to specified clampload. Rotate drum 180 degrees and again tighten top bolts to their required clampload. Follow this procedure until all bolts are at their required clampload which should only be measured while bolt is at top of drum so that drum weight does not affect actual clampload.

4-33

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EM029421-0 (en-us)

Each DRAG DRUM end casting has a machined integral bearing journal. Two large diameter spherical roller bearings are mounted on the journals inside bearing housings which are pinned to the drum support pedestal and the gear case.

(

On the gear end of the drum, the bearing cup is fixed in place against the bearing retainer flange. On the other (pedestal) end of the drum, the bearing cup floats in the housing.

Hand pack bearings at assembly with MPG multi-purpose grease.

Intermediate Shaft Pinion (55481bs.)

Motor Coupling (Typ,)

Intermediate Shaft Pinion (5548 lbs.)

Gear Case

""'

NOTE: Case drains are under Case inside Rotating Frame

.........

.........

'-....

""'-, 9.62 Oil Level (Two Places)

Gear Case Capacity: 95 U.S. gal . each case (Fill at Air Filters) Total Weight of Gear Case is 101,950 lbs.

DRAG GEAR CASE AND DRUM ASSEMBLY

( 4-34

EM029421-0 (en-us)

THE DRAG INTERMEDIATE SHAFT ASSEMBLY drives the drum gear. )t consists of a large double helical gear, a double helical pinion, a shaft, bearings and a bearing housing.

The intermediate gear and pinion are splined to the intermediate shaft which is supported by two single row roller bearings. The bearing on the drive gear end of the shaft is mounted in the boss of the gear case while the other bearing is mounted in a housing which is pinned to the gear case structure.

The intermediate shaft pinion is a guarded open gear which drives the drum gear.

Intermediate Shaft Assembly (Typ. 2 Places) (22890 lbs.)

4-35

EM029421-0 (en-us)

End Plate

Intermediate Shaft

Retainer

.j:::.

I w

0')

Gear

NOTE: This assembly used in both Drag and Hoist Machinery.

INTERMEDIATE HOIST/DRAG SHAFT ASSEMBLY

~

,/~,

EM029421-0 (en-us)

Bearing Housing (3130 lbs.)

NOTE: Wire Lock Cap Screws in Pairs at each end of Shaft

Auto Lube Point End Plate (921bs.)

Spacer Retainer (30 lbs.) Intermediate (122 lbs.)

Gear (7300 lbs.)

Pin (891bs.)

Pinion (6010 lbs.)

At Assembly, Coat O.D. of Shaft in Seal Area with Molycote M-3402. Install Seal with split at top.

Gear Case

Bearing Retainer (122 lbs.)

Torque to 280 ft-lbs.

Trim 0-Ring to length. Install with splice at top and bond ends together with Locktite 65-51 No. 404. Use a small amount of grease to hold in place during assembly.

Install Shims to Reduce Gap to .01 Maximum for clamping Pinion onto Shaft VIEW A

VIEWS

INTERMEDIATE SHAFT ASSEMBLY

4-37

EM029421-0 (en-us)

Retainer

Gasket

_A

0-Ring Eccentric Bearing Housing

(

Sleeve

I I

+:-

I

I I I

1

w CX)

I I I

I .)

Gasket

Gear Case Grid Coupling See Section 7 for Assembly/Disassembly

HOIST OR DRAG MOTOR EXTENSION SHAFT ASSEMBLY

/~

-~.

EM029421-0 (en-us)

Eccentric Bearing Housing 0-RING INSTALLATION Trim a-rings to length at assembly. Install with splice at top and bond ends together with Locktite 65-51 No. 404.

Use a small amount of grease to hold in place during assembly.

Retainers (60 lbs.)

Retainer (15 lbs.)

Lock Wire in Pairs (Typ, each Eccentric) Direction of Lip on Seal

Sleeve

Gasket

0-Ring Lock Wire in Pairs Shaft (6831bs.)

Lock Plate (15lbs.)

Eccentric Bearing Housing (81 lbs.)

Eccentric Bearing Housing (81 lbs.)

HOIST OR DRAG MOTOR EXTENSION SHAFT ASSEMBLY NOTES:

1. Sleeve is interference fit. Heat to expand for assembling, make sure bearing race is tight against shaft shoulder and sleeve is tight against bearing race.

2. Coat O.D. of sleeve in seal area with Belray silicone valve seal lubricant.

3. Pack cavity between seal and retainer with Bel ray silicone valve seal lubricant. Replenish with grease gun furnished in tools and supplies.

4-39

EM029421-0 (en-us)

Disassemble drag gear case by removing gear guards and case cover bolts. Remove cap screws from top half of bearing retainers of intermediate shaft assemblies and from top half of eccentric housings of motor extension shaft assemblies. Loosen cap screws (about two turns) located in bottom half of bearing retainers and eccentric housings. Remove split oil seals from intermediate shaft assemblies. Lift case covers from case.

(

Remove split collars from intermediate shaft bearing housing pins and then remove pins.

Remove cap screws from lower half of bearing retainers and eccentric housings. Using sling around shaft, lift out intermediate shaft assembly while slowly rolling both intermediate shaft and hoist drum to allow intermediate shaft to roll out of engagement.

Next, disconnect motor couplings and remove motor extension shaft assemblies from case.

Move No. 2 and No. 3 drag motors to remove those shafts. Drain and clean gear case and flush out with light oil. Reverse procedure to reassemble gear case. Reassemble motor shaft couplings in accordance with Engineering Data Section 7.

NOTES:

( 4-40

EM029421-0 (en-us)

HOIST MACHINERY consists of a drum driven by five mill type D.C. motors. The drum is mounted on a left hand gear case and a right hand gear case. The left hand case has two double reduction gear trains with two intermediate shafts and three motor extension shafts.

The right hand case has one double reduction gear train with one intermediate shaft and two motor extension shafts.

Hoist Drum Assembly ( 173368 lbs.)

Tension Rods to 246,260 lbs. or Torque to 12,315 ft-lbs.

Intermediate Shaft Assembly (25324 lbs.)

Oil Dip Stick ....._ Note: Case drains are under case inside Rotating Frame

Gear Case L.H. Fill at Air Filters 95 U.S. gal. GL per end, total 190 gal.

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

Motor Extension Shaft Coupling

' 9.62 Oil Level (Three Places)

Total Weight of Left Gear Case- 105,000 lbs.

Total Weight of Right Gear Case- 63,290 lbs.

HOIST GEAR CASES AND DRUM ASSEMBLY HOIST DRUM is an assembly of two rope lagging sections bolted together at the center with rod bolts. The drum end castings and gear hubs are rod bolted to the lagging. The split double helical drive gear halves are joined together and mounted on the drum ends. There are two main drive gears.

4-41

EM029421-0 (en-us)

NOTE: All drive gear bolts should be checked after the first week of operation and every 500 hours thereafter.

(

Each drum end casting has a machined integral bearing journal. Two large diameter spherical roller bearings are mounted on the journals inside bearing housings which are pinned to pedestals on the gear case structures. On the left hand side of the drum, the bearing cup is fixed in place between the inner and outer retainers. On the right hand side of the drum, the bearing cup floats in its housing.

Hand pack the drum bearing at assembly with MPG multipurpose grease.

HOIST INTERMEDIATE SHAFT ASSEMBLIES drive the drum gears. These assemblies are identical to the intermediate shaft assemblies described in the drag machinery section of this manual.

DISASSEMBLE HOIST GEAR CASES by removing case cover bolts. Remove cap screws from top half of bearing retainers of intermediate shaft assemblies and from top half of eccentric housings of motor extension shaft assemblies. loosen cap screws (about two turns) located in bottom half of bearing retainers and eccentric housings. Remove split oil seals from intermediate shaft assemblies. Lift case cover from case.

Remove split collars from intermediate shaft bearing housing pins and remove pins.

Remove cap screws from lower half of bearing retainers and eccentric housings. Using sling around shaft, lift out intermediate shaft assembly while slowly rolling both intermediate shaft and hoist drum to allow intermediate shaft to roll out of engagement.

Next, disconnect motor couplings and remove motor extension shafts from case. Drain and clean gear case and flush out with light oil. Reverse procedure to reassemble gear cases.

Reassemble motor shaft couplings in accordance with Engineering Data Section 7.

( 4-42

EM029421-0 (en-us)

Drum End (24537 lbs.)

Rope Clamps Lagging (23040 lbs.)

Drum End (24537 lbs.)

Bearing Housing (37741bs.)

Retainer (165 lbs.)

Retainer (148 lbs.)

I

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I

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I

NOTE: Cap Screws in Retainers at each end of drum to be wire locked in pairs.

*Tension Rod Bolts to 246,260 lbs. or Torque to 12,315 ft-lbs.

Use Witness Holes for alignment of drums and drum ends.

Weight of Assembly is 113,520 lbs.

HOIST DRUM SHAFT ASSEMBLY (Viewed from rear of Machine) TIGHTENING NOTE FOR HOIST DRUM RODS: Use hydraulic tensioner (bolt stretcher) to apply a clampload in 3.00 inch dia. finished rods of 246,260 lbs. If tensioner cannot be used, torque to 12,315 ft.lbs.

DRUM SHAFT ASSEMBLY INSTRUCTIONS: 1. All finished drum end surfaces should be free of metal chips and surface obstructions.

Clean all finished drum end surfaces with an approved solvent without an oil base and wipe dry before assembly.

2. Install bearings and housings on drum ends; ensure that correct housing is used on correct drum end. Assemble housings with cast note "outside" facing away from drum.

3. Install drum ends on drum barrels using witness holes for alignment of drums and drum ends. Tighten rod bolts to approximately 70% of their required clampload or torque.

4. Using hydraulic tensioner, tighten rod bolts at top of drum to specified clampload. Rotate drum 180 degrees and again tighten top bolts to their required clampload. Follow this procedure until all bolts are at their required clampload which should only be measured while bolt is at top of drum so that drum weight does not affect actual clampload.

4-43

EM029421-0 (en-us)

Cover (3310 lbs.)

(

Intermediate Shaft Assembly (Typ. two places) (25324 lbs.)

Total Weight- 105,000 lbs.

Hoist Motor Extension Shaft with Grid type Coupling (Typ. three places)

HOIST GEAR CASE- LEFT HAND

( 4-44

EM029421-0 (en-us)

Pin (89 lbs.)

(Typ. two places) /

I

I I • II II ' I I I I (

Hoist Motor Extension Shaft with Grid type Coupling (Typ. two places) Total Weight- 63,290 lbs.

HOIST GEAR CASE- RIGHT HAND

4-45

EM029421-0 (en-us)

HOIST, DRAG, SWING AND PROPEL BRAKES - These brakes are disc type, spring applied and air released. Braking in these motions is available if loss of air supply and/or loss of electrical power occurs. The swing brake design is single disc while the hoist, drag and propel brakes are dual disc.

(

CAUTION: These brakes are rated for parking, not operation. Dynamic braking application will greatly accelerate wear.

OPERATION - When air is exhausted, the spring force "Clamps" the disc between the friction discs or the mounting flange and pressure plate. To disengage the brake, air enters thru the end plate into the diaphragm cavity. As air pressure increases, the end plate moves away from the stationary spring housing. The pressure plate is bolted to the end plate and travels in the same direction with it compressing the springs and releasing the brake.

DANGER:

A ~

WARNING:

Prior to installation or maintenance on brake, make sure that machine will remain in a safe position. Failure to do so could result in serious personal injury or machine damage.

Protective means must be used to prevent oil or grease from coming into contact with the disc(s) or the friction discs. Oil or grease will significantly reduce the torque capacity of the brake and decrease its ability to hold the machinery in a safe position. DO NOT RISK INJURY!

MOUNTING - Brake is mounted with 1"- SNC-2 screws (torque 200 ft.lbs. or 270 Nm).

The brake must be concentric and at right angles to the motor shaft.

The driving gear must be positioned axially along the shaft so that the disc will not run out of travel as the friction discs wear. It is important to prefit the key in both the gear and the shaft keyways. Check the bore, with respect to the shaft diameter, to assure proper fit at assembly.

( 4-46

EM029421-0 (en-us)

MOUNTING FLANGE

FRICTION DISC

FRICTION DISC

DISC

SPRING RETAINER

SPRING HOUSING

~

I

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-..J

SOC HD CAP SCREW & LOCKWASHER

REWORKED SCREW

SPRING

SWING DISC BRAKE

1!!11

OUTER CLAMP RING

DIARHRAGM

END PLATE

EM029421-0 (en-us)

( Lifter Guard Use Nut and Lockwasher supplied with Motor. Discard Nut supplied with Brake

Disc Centering Adjustment Screw

Jam Nuts

Air Line Connection

Outer Shield

Center Disc Between Friction Disc with Air Pressure Applied (Brake Released) Friction Disc

Motor

DANGER:

Make sure power to motor is off before removing outer shield and lifter guard.

Figure A SWING BRAKE MOUNTING

After the swing brake (single disc unit) has been installed, the disc must be centered, see Figure A: 1.

2.

Remove the outer shield and lifter guard.

Bypass any interlocks or use manual overrides on air valves so that static actuation may be made.

3. Remove the top hex jam nut. Release the brake.

4. Hold bottom nut and turn the adjusting screw to obtain equal running clearance between disc and each friction disc.

5. With clearance established, install top hex jam nut and tighten.

6. Remove bypasses and interlocks which may have been used and reinstall the shield and lifter guard.

( 4-48

EM029421-0 (en-us)

A.

BRAKE ADJUSTMENT - Single disc brakes do not have a provision for adjustment.

The dual disc brakes do provide for adjustment should the running clearance become excessive as explained below:

DANGER:

A''

Prior to adjustment or disengagement of the brake, make sure that machine will remain in a safe position. Failure to do so could result in serious personal injury or possibly death.

To determine if the running clearance is excessive, release air (engage brake), remove shield, and measure the distance "A" as shown in Figure B. If this dimension is less than 4.562 inches ( 11.587 em), adjustment is done as given below. If dimension is greater, adjustment is not required. Replace shield.

:spring Housing

End Plate

Figure B

4-49

EM029421-0 (en-us)

I

1. Remove locknuts, in alternating sequence as shown in Figure C, in increments of 1/4 of the exposed stud thread length.

~

0)001':"\ 0 \!; 0 0

CAUTION: If stud comes loose from mounting flange, clean stud threads thoroughly. Apply Loctite 277 or equivalent. Thread stud back into mounting flange hole until it bottoms.

0~0 ~ Figure C

2. With locknuts removed, the end plate, spring housing and pressure plate can be removed as an assembly. See Figure

Wear Spacer:

B. 3.

Remove wear spacers from studs. See Figure D.

4.

Reassemble the end plate, spring housing, and pressure plate on the studs as assembly with wear spacers now located on the outside of the spring housing. See Figure E.

FigureD

5. Lubricate stud threads with 30 weight oil or "Never Seez". Assemble locknuts on studs and torque to 200 ft. lbs. (271 Nm) using sequence shown in Figure C.

· Wear Spacer

CAUTION: After adjustment, a minimum of 0.040 inch (0.1016 em) running clearance must exist between each friction disc and each disc. ·Figure E 6. Reinstall shield.

( 4-50

EM029421-0 (en-us)

B.

INSPECTION OF FRICTION DISCSTo determine if friction discs need to be replaced, release air (engage brake), remove shield, and check if the wear indicating step on the friction disc is still visible. Also check if oil or grease has contaminated the surfaces. If the step is visible and the surfaces are not contaminated, no replacement is necessary. Reinstall shield. If the step is not visible, or if surfaces are contaminated, friction disc must be replaced. See Figure F.

Friction Disc (1 of 4)

C.

Figure F

REPLACEMENT OF FRICTION DISCS ON SINGLE DISC BRAKE (SWING)-

DANGER: Prior to disengagement of the brake, make sure machine will remain in a safe position. Failure to do so could result in personal injury or death.

Figure G 1.

Remove locknuts in alternating sequence in increments of 1/4 of the exposed stud thread length. See Figure G.

A

CAUTION: If a stud comes loose from the mounting flange, clean stud threads thoroughly. Apply Loctite 277 or equivalent. Stud must be threaded back in until it bottoms in mounting flange.

2. With locknuts removed, end plate, spring housing, and pressure plate can be removed as an assembly.

3.

Remove disc from gear. Inspect disc for wear. If either surface of the disc is worn more than 1/32 inch (.7938 mm), replace the disc. Removal of the disc from the gear will expose the friction disc mounted on the brake mounting flange.

4.

Remove old friction discs and replace with new friction discs and new flat head screws.

Torque screws to 20 ft.-lbs. (27 Nm).

4-51

EM029421-0 (en-us)

(

5.

Reinstall the disc.

6.

Reassemble end plate, spring housing, and pressure plate as an assembly.

7.

Lubricate stud threads with 30 weight oil or "Never Seez".

8.

Assemble locknuts in alternating sequence as shown in Figure G. Torque locknuts to 200 ft.lbs. (271 Nm).

9.

Reinstall shield.

D.

REPLACEMENT OF FRICTION DISCS ON DUAL DISC BRAKE (HOIST, DRAG, AND PROPEL)-

A 1.

DANGER: Prior to disengagement of the brake, make sure machine will remain in a safe position. Failure to do so may result in personal injury or death.

Remove locknuts in alternating sequence in increments of 1/4 of the exposed stud thread length. See Figure G.

A

CAUTION: If a stud comes loose from mounting flange, clean stud threads thoroughly. Apply Loctite 277 or equivalent. Stud must be threaded in until it bottoms in mounting flange.

2.

With locknuts removed, end plate, spring housing, and pressure plate can be removed as an assembly.

3.

Remove springs, clamp tubes, discs, and reaction plate. With these parts removed, all friction discs are accessible.

4.

Inspect discs for wear. If either surface of the disc is worn more than 1/32 inch (.7938 mm), replace the disc.

5.

Remove old friction discs and replace them with new friction discs and new screws.

Torque screws to 20 ft.-lbs. (27 Nm).

( 4-52

EM029421-0 (en-us)

6.

Reassemble springs, clamp tubes, discs, and reaction plate

A

CAUTION: Springs are to be assembled on every other stud. Improper assembly will result in cocking of the reaction plate and uneven brake release.

7.

Reassemble wear spacers, end plate, spring housing and pressure plate as an assembly.

8.

Lubricate stud threads with 30 weight oil or "Never Seez". Assemble locknuts using assembly sequence shown in Figure G. Torque locknuts to 200 ft.-lbs. (271 Nm).

A 9.

E.

CAUTION: While reassembling the end plate, spring housing, and pressure plate assembly, take care to install wear spacers in the proper position.

See Figure D.

Reinstall shield.

REPLACEMENT OF SPRINGS is done by the following steps:

A

DANGER:

Prior to removal of the brake, make sure that the machinery will remain in a safe position.

1.

Remove the brake from the machine, place it on a clean working surface with the end plate facing up and remove the shield.

2.

Remove locknuts in alternating sequence (as shown in Figure G) in increments of 1/4 of exposed stud thread length. If a stud comes loose, clean threads thoroughly, then apply Loctite 277 or equivalent. Thread stud back in until it bottoms in mounting flange.

3.

Remove the end plate, spring housing and the pressure plate as an assembly.

4.

Remove hex head screw and lockwasher from end plate in alternating (see Figure H) sequence two turns at a time. The end plate diaphragm, outer clamp ring and inner-clamp ring can be removed as an assembly.

4-53

Figure H

EM029421-0 (en-us)

5.

Remove spring housing exposing the springs and spring retainer plates.

6.

Remove spring retainer plates exposing the springs.

7.

Replace springs.

8.

Install spring retainer plates. No spring retainer plates should cross over the ribs in the spring housing.

(

Clean the rubbing surfaces between the spring housing and pressure plate and coat with molybdenum disulfide grease. This helps prevent wear between these parts.

9.

Install the spring housing, making sure the pockets line up with the pockets on the pressure plate.

10.

Reassemble end plate, diaphragm, outer clamp ring and inner clamp ring as an assembly.

Assemble hex head screws, with lockwashers in end plate, using the same sequence as they were removed. See Figure H. Torque screws to 100 ft.-lbs. (135 Nm).

11.

Reassemble the end plate, spring housing and the pressure plate as an assembly.

12.

Lubricate stud threads with 30 weight oil or "Never Seez". Assemble locknuts using the same sequence as they were removed. See Figure G. Torque locknuts to 200ft.lbs. (271 Nm).

13. Reinstall shield and then reinstall brake on machine. See MOUNTING and STATIC ADJUSTMENT PROCEDURE.

F.

REPLACEMENT OF DIAPHRAGM- To install a new diaphragm, proceed as follows:

A

DANGER:

Prior to removal of the brake, make sure the machinery will remain in a safe position.

1.

Remove the brake from the machine, place it on a clean working surface with the end plate facing up. Next remove the shield.

2.

Remove hex head screw from end plate in alternating sequence, two turns at a time (see Figure H). The end plate, diaphragm, outer and inner clamp ring can be removed as an assembly.

( 4-54

EM029421-0 (en-us)

3.

Place the end plate with the diaphragm up. Remove the hex head screws to remove the outer clamp ring.

4.

Remove the hex head screws holding the inner clamp ring, then remove ring.

5.

Inspect and replace diaphragm as required.

6.

Reinstall outer clamp ring and torque hex head screws to 20 ft.-lbs. (27 Nm).

7.

Reinstall inner clamp ring and torque hex head screws to 20 ft.-lbs. (27 Nm).

8.

Carefully place newly assembled end plate, diaphragm, and outer and inner clamp rings on the brake. Assemble end plate hex screws using the same sequence as they were removed. See Figure H. Torque screws to 100 ft.-lbs. (135 Nm).

9.

Reinstall shield, then reinstall brake on machine. See MOUNTING and STATIC ADJUSTMENT PROCEDURE.

G.

SYSTEM STATIC ADJUSTMENT PROCEDURE - Before the machine is placed in operation, a static actuation check of the brake is recommended as follows:

DANGER:

Prior to adjustment, make sure that the machinery will remain in a safe position.

1.

Bypass any interlocks or use manual overrides on actuation valve.

2.

Check for proper air pressure in air receiver tank.

3.

Check for "all clear" in and around machinery.

4.

Energize actuation valve.

5.

Check for air leaks- correct as required.

6.

De-energize actuation valve.

7.

Repeat steps 4 and 6 several times.

8.

Reset any interlocks which may have been bypassed in step 1.

4-55

EM029421-0 (en-us)

HOIST AND DRAG ROPES are subjected to the greatest wear at or near the bucket. If ropes show excessive wear in this area, worn area should be seized, cut off and resocketed.

Be sure to reset drum limit switch.

(

The ropes are expendable items. The operator should make a habit of watching the ropes during the digging cycle for damage, broken wires and wear.

There are two hoist and two drag ropes, each 3-3/4 inch in diameter, 6 x 49 lang lay, monitor improved plow steel, excellay preformed special wire rope with IWRC, with becket loop on each end. Each hoist rope is 820 feet long. Each drag rope is 535 feet long, which includes rope required for boom raising. Replacement length for drag rope is 510 feet.

The hoist and drag ropes are reeved as shown in sketch.

The ropes are anchored at center of drum with six U-bolts for each rope. Thread rope thru the six U-bolts and allow at least 16 inches of rope to extend past last U-bolt. Reeve at least two dead wraps on drum.

NOTES:

( 4-56

EM029421-0 (en-us)

Winch Lines -----"'\

CHANGE HOIST ROPE(S) by disconnecting them from bucket rigging. Unwind hoist rope from drum.

CAUTIOUSLY pull rope away from machine with dozer or truck, BUT use care to keep rope from boom point sheave(s) to ground perpendicular as possible. See sketch.

Reeve winch rope and attach it to one hoist rope at drum. Remove hoist rope from drum clamps. Operate winch to remove hoist rope from machine. Reverse procedure to reassemble hoist rope. Attach winch rope to other hoist rope and replace it in same manner.

NOTE: Reset drum limit switch after changing rope(s). instruction manual.

4-57

See Marion Protection System

EM029421-0 (en-us)

(

Tri-Structure

CHANGE DRAG ROPE(S) by disconnecting them from bucket and unwinding rope from drum. Pull ropes away from machine with dozer or truck.

Reeve winch and attach it to one drag rope at drum. Remove rope from clamps on drum.

Operate winch to remove drag rope from machine.

Reverse procedure to reassemble drag ropes. Attach winch rope to other drag rope andreplace it in same manner.

NOTE: Reset drum limit switch after changing rope(s). instruction manual.

See Marion Protection System

METHOD OF LOWERING BOOM - Position machine on near level ground as possible.

This spot should be solid ground and have good drainage. Obtain cribbing to support boom and place under rear of machine to prevent rear end settling when there is no boom load.

Set up and maintain communication between workmen at the various locations and machine operator.

Disconnect the hoist and drag ropes from the bucket. Swing machine clear of bucket and set swing brakes. Remove all hoist and drag ropes from the machine. The drag ropes are 510 feet long. Drag ropes, 535 feet long, will be required to lower boom.

Remove all lube lines from points on top of tri-structure. Plug lines and points to prevent dirt from entering. Lubricate the bushing and grooves of the sheaves on top of tri-structure and sheaves at rear of tri-structure near top back leg connection.

Reeve auxiliary winch ropes as shown in Views A and B.

( 4-58

EM029421-0 (en-us)

Symmetrical About Centerline

Aux. Winches

Hoist Drum

I

----1.,____ + ___..,:c:::==:..._ To Sheaves

To Sheaves on Top of Tri-Structure

VIEW A Showing Winch Rope Reeving for Pulling in Boom Raising Ropes and Intermediate Ropes.

Top of Deck

VIEWB

WINCH ROPE REEVING

4-59

EM029421-0 (en-us)

The following steps are applicable to both left and right sides of tri-structure and boom:

Tri-Structure Head Assembly

(

Reeve auxiliary winch wire rope over front and rear sheaves on top of tri-structure.

Attach winch rope to intermediate support rope. Release tension on intermediate support rope, remove pins from rope link and lower rope to top of boom.

Disconnect winch rope and secure intermediate rope to top of boom.

See View C.

ViewC

Attach winch rope to socketed end of boom raising rope (furnished by customer) and pin rope socket to dead end on tristructure as shown in View D.

0

Use winch rope to reeve free end of boom raising rope around sheave on support rope bridle and over sheaves on tristructure. See View E. Clamp boom raising ropes to drag drum.

Equalize ropes.

NOTE: Rope equalization is very important!

A

Grease curved plate to help rope to slide when picking up Sheave Block (Boom Raising)

Boom Raising Rope

Tri-Structure Head Assembly

ViewD

CAUTION: Check drag brakes for proper shoe adjustment and maximum braking force.

Increase tension on boom ratsmg ropes until support rope bridle pins can be removed.

SLOWLY and CAUTIOUSLY lower boom to within three or four inches of desired ground position. SET BRAKES.

( 4-60

EM029421-0 (en-us)

----To Rear Sheave and Drag Drum

View E

Force cribbing under boom and finish lowering boom onto cribbing which should be positioned at vertical side lacing where two or three diagonal side lacings are welded to lower chord. Each support point should span three or more feet of lower chord to spread load.

See View F.

Tri-Structu re Head Assembly

Lower boom support ropes to top of boom. This is a good opportunity to check condition of boom, ropes, dampers and gaskets between wood block spacers on support ropes.

Boom Support Ropes

8'

View F - Placement of Cribbing METHOD OF RAISING BOOM- This method uses auxiliary winch ropes and boom raising ropes to raise boom by pulling up support ropes to top of tri-structure.

NOTE: Some procedures described will have been previously accomplished if boom is lowered in accordance with instructions in this manual section.

4-61

EM029421-0 (en-us)

(

Reeve winch ropes as shown in Views A and B, then reeve winch ropes over sheaves on top of tri-structu re.

Boom Raising Rope

Attach each winch rope to socketed end of each boom raising rope (furnished by customer) and pin rope sockets to dead end on tri-structure as shown in View D. NOTE: All procedures apply to both winch ropes and both boom raising ropes.

/

/\

Use winch rope to reeve free end of boom raising rope around sheave on support rope bridle and over sheaves on top of tri-structure. See View G.

Tri-Structure Head Assembly

Support Rope Bridle (In Ground Position) (74391bs.)

Clamp boom raising ropes to drag drum.

Equalize rope lengths by allowing them to slip in rope clamps.

Then tighten clamps.

ViewG

NOTE: Rope equalization is very important!

Operate drag control lever to raise boom support ropes to tight position, then raise boom three or four inches off cribbing. SET BRAKES. If brakes hold in this position, they will hold boom at any angle.

After testing brakes, SLOWLY and CAUTIOUSLY raise boom until pin bore of support rope bridle aligns with pin opening in tri-structure. Install pin thru larger part of opening in tri-structure. Slowly release tension in boom raising ropes until bridle pins seat in tri-structure and are in operating position. Install pin retainers. See View E. Remove boom raising ropes and use auxiliary winch ropes to raise and pin intermediate support ropes to tri-structure. See View C. Adjust pre-load tension of intermediate ropes in accordance with instructions in this manual.

( 4-62

EM029421-0 (en-us)

Remove winch ropes and snatch blocks. Reconnect all lubrication lines.

Reinstall hoist and drag ropes. Be sure to reset hoist and drag drum limit switches in accordance with Marion Protection System instruction manual.

BOOM POINT SHEAVE ASSEMBLY consists of two single groove sheaves mounted on a shaft and trunnion assembly. Each sheave turns on two tapered roller bearings. Trunnion allows sheave assembly to rotate to follow fleet angle of hoist ropes.

DISASSEMBLY OF BOOM POINT SHEAVES requires removal of hoist ropes and removal of sheave assembly from boom point structure. Four pins secure the two trunnion bearing housings to boom point structure. Disconnect lubrication lines and hook up auxiliary crane to lifting lugs on top of trunnion.

A

CAUTION: Weight of sheave assembly is 4 7,280 pounds.

Remove four trunnion bearing housing pins and lower sheave assembly to rest on cribbing at ground level. Sheave shaft should be horizontal for disassembly of sheaves.

Remove retainer bolts and two end retainers and pull sheaves from shaft. Remove, clean, inspect and replace parts as required.

A

CAUTION: Weight of each sheave is 11,610 pounds.

Weight of shaft is 3,960 pounds.

NOTES:

4-63

EM029421-0 (en-us)

Pin (Typ. 2 Places) (57 lbs.)

Pin (Typ. 2 Places) (391bs.)

Auto Lube Point Each End of Shaft

Rear Bearing Block (4440 lbs.)

Install Shaft so this Lube Hole points downward perpendicular to centerline of Boom and Trunnion

Auto Lube Point

Shaft Retainer

.j:>.

Bushing

I

Bushing

(j) .j:>.

Shaft Retainer

Auto Lube Point Sheave (11610 lbs.)

Trunnion (10930 lbs.)

Bearings Retainer (Typ. both ends) (164 lbs.)

Retainer (Typ. each side of Sheave) (200 lbs.) /

:1

\

L_____- - ----' I

NOTE: Total Weight 47280 lbs.

BOOM POINT SHEAVE ASSEMBLY- PLAN VIEW

~.

.~

EM029421-0 (en-us)

Boom Point Structure

Rope Guard

-'=='

I

C) (J1

Front Bearing Block

Trunnion Assembly

BOOM POINT SHEAVE ASSEMBLY- SIDE VIEW

lml

EM029421-0 (en-us)

POINT SHEAVE BEARING ASSEMBLY PROCEDURE: 1.

Make sure shaft is clean and free from foreign material including tapped holes in ends of shaft and grease access holes in shaft.

2.

Press cups into sheaves and complete assembly except for bearing retainer bolts and shims.

(

NOTE: Shaft to be horizontal during assembly.

3.

Install only four lubricated bearing retainer bolts, equally spaced on bolt circle, making sure that bolts can be snugged up freely by hand.

4.

Oscillate or rotate bearings to assure that all bearing components are properly seated while torquing each of these four bolts to 905 ft-lbs.

5.

Back off torque on bolts and retorque each of four bolts to 125 ft-lbs in a crosshatch pattern. Oscillate or rotate bearings to assure rollers are properly seated against cone rib. Again torque bolts to 125 ft-lbs.

6. Measure gap between retainer and end of shaft as near to bolts as possible (average these measurements).

7.

Remove retainer bolts and retainer and install a shim pack of thickness equal to average of measured gaps.

8.

Reassemble bearing retainer with shim pack in place and torque all bolts to 905 ft-lbs.

Wire lock bolt heads in pairs.

REASSEMBLY OF BOOM POINT SHEAVE ASSEMBLY may be accomplished as follows: 1.

Install shaft in trunnion and secure with retainers. Install shaft so that lube holes point downward perpendicular to centerline of boom and trunnion.

2.

Install sheave bearings and sheaves in accordance with method described in "Point Sheave Bearing Assembly Procedure".

3.

Install front and rear bearing blocks and retainers.

4.

Using auxiliary crane, raise sheave assembly and install in boom point structure with four pins thru bearing blocks. Reconnect lubrication lines.

NOTE: Pins should have coating of Molycote M3402 prior to assembly.

( 4-66

EM029421-0 (en-us)

Four BOOM SUPPORT BRIDGE STRANDS, two each side, support the boom. Each strand is 3-1/4 inches in diameter, 249 feet long (pin to pin) galvanized, prestressed and striped.

Rope Assembly (8703 lbs.)

Boom Lowe:g Sheave

I

A

Tri-Structure End

~A

Damper (Typ. each end of Rope) Wood Block Rope Spacer Rope Spacer (107 lbs.)

Manual Lube Point

*Denotes Auto Lube Point

*

SECTION A-A

The ropes are pinned at the boom point and to an equalizer link at the tri-structure connection. The stripe on the strand MUST NOT, at any time, have a twist, from boom point to equalizer link.

The ropes are interconnected with wood blocks to dampen rope oscillation. This reduces rope fatigue at end socket.

4-67

I

EM029421-0 (en-us)

The VIBRATION DAMPER located at end of the boom support bridge strand should be inspected on a regular basis. All bolts should be retightened using a torque wrench. (150 foot-pounds for 3/4 inch bolts). If any bolts are broken or missing, replace them with structural Grade A325 or SAE Grade 5.

(

Grease (Lubriplate 630AAA or equivalent) should be applied thru the fittings on the damper flange when inspection is made.

At six month intervals, a damper should be removed for examination of the strands that are inside. If the first one is found in bad condition, remove the others and inspect. The fabric liner should be saturated with light lubricant if dry.

Use Lubriplate 630AAA or equivalent only.

VIBRATION DAMPER

( 4-68

EM029421-0 (en-us)

ADJUSTMENT OF INTERMEDIATE BOOM SUPPORT ROPES- Applicable to machine Key No. 82025, Serial No. 23298; Key No. 82026, Serial No. 23299; and Key No. 82027, Serial No. 23300.

Intermediate support ropes on this machine require pre-load tension of 78,400 pounds which is obtained as follows: Lower bucket to ground and slacken hoist ropes. Back off adjusting nut at point "A" just enough to allow required take-up. Tighten nut at point "B" until nut is against hydraulic jack and jack is bottomed.

Lube Fitting

Tri-Structu re Connection Auto Lube Fitting

Connect hydraulic pump to jack and operate pump until pressure gauge on pump reads 4345 psi. At this point, pressure is 15% to 20% above normally required pressure. Tighten adjusting nuts at point "C" as snug as possible.

SLOWLY release pressure on jack and observe reading at point where gauge needle drops rapidly. This point should be at required pressure setting of 3700 psi, with adjusting nuts at point "C" taking up load. When required pressure (3700 psi) is obtained, tighten adjusting nut at point "A".

Repeat procedure on other rope, if both ropes have not been tightened at the same time. Keep tension difference between ropes at 7000 pounds or less (10% of required pressure). It is advisable to check and record pressure as often as necessary to hold pressure within 20% of required 3700 psi.

4-69

EM029421-0 (en-us)

TRI-STRUCTURE ASSEMBLY is a welded structure connected by pins to front girder of rotating frame and to back leg assembly. Back legs and two safety ropes anchor tri-structure assembly to rotating frame deck. Boom support rope bridles and intermediate support ropes are attached to top of tri-structure. Hoist ropes are routed thru tri-structure over deflecting sheaves.

(

Hoist Rope Deflecting Sheaves Float Sheaves (Tri-Structure)

Float Sheaves (House Roof)

TRI-STRUCTURE ASSEMBLY

Two HOIST ROPE DEFLECTING SHEAVES are located in the upper front section of the tri-structure assembly. These sheaves lead the hoist ropes from the boom point to the hoist drum.

Each sheave is supported by a fixed shaft and rotates on two single row roller bearings.

Bearings are assembled into the sheave with a machined spacer between the cones for accurate alignment and adjustment.

( 4-70

EM029421-0 (en-us)

Bearings (1741bs.)

END VIEW (Typical)

Spacer Sleeve (1241bs.)

Bearing Spacer (70 lbs.)

A.

CAUTION: Secure Sheave . . before removing Shaft.

HOIST ROPE DEFLECTING SHEAVE- TAl-STRUCTURE

If the bearings must be replaced, remove the sheave assembly from the tri-structure by removing the lockplate and the retainer. Push shaft out from the inside and lower the sheave to the ground.

4-71

EM029421-0 (en-us)

To REPLACE DEFLECTING SHEAVE BEARINGS, the following procedure is applicable to each sheave and set of bearings. Remember to matchmark parts for assembly.

(

1. Chill and install bearing cups in sheave.

2. Assemble cone/roller assembly and clamp with jig J-14406-1 and tighten jig bolts until bearings bind slightly when rotated.

3. Measure distance between cones (gap "A") with inside micrometer at 3 places 120 degrees apart.

Calculate average dimension. Machine bearing spacer to calculated average dimension minus 0.002 to 0.004.

4.

Remove jig and install sheave and bearings on shaft with machined spacer between bearings.

Note: Hand pack bearings with multi-purpose grease before assembly.

Jig J-14406-1

5.

Reinstall bearing retainers.

6.

Lubricate shaft and bearing assembly thru shaft fitting.

( 4-72

EM029421-0 (en-us)

Shaft

/(5611b•.l

Ma nual Lub e Fitting

\~

Manual Lube Fitting

/

rr

1:?

rr

~

I

-

I

+

0

/j

I

Aut 0 Lub e Fitting

Shaft (1880 lbs.)

1/

I

I

+

G

0

1_1\

I

~ Sheave (1580 lbs.)

/

Auto Lube Fitting

~

HOIST ROPE FLOAT SHEAVES- HOUSE ROOF

Manual Lube Fitting

Manual Lube Fitting

Shaft (391 lbs.)

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

Auto Lube Fitting

0

0

=- -=- -=. == ==--=--=--- -=0

Shaft (15601bs.)

Sheave (1580 lbs.)

HOIST ROPE FLOAT SHEAVES- TRI-STRUCTURE

4-73

0

EM029421-0 (en-us)

Two SAFETY ROPES are installed for the tri-structure, one at each backleg. These bridge strand ropes are attached between the tri-structure and the rotating frame to support the tri-structure in the event of failure of backlegs, pins, etc. Adjust ropes so that there is approximately six inches of sag.

Tri-Structure

1710.5 installed length includes 6 inch sag at mid-point

Rotating Frame

TRI-STRUCTURE SAFETY ROPES

4-74

(

EM029421-0 (en-us)

FAIR LEAD ASSEMBLY is pinned to upper frame front girder between attachment points for tri-structure assembly. Frame structure of fairlead assembly is supported by back legs which pin to upper frame deck.

Drag ropes from bucket enter fairlead assembly under lower sheaves and then are reeved up thru rope guards and over upper sheaves to drag drum. Lower sheaves swivel to follow bucket motion, eliminating side loads on sheaves and drag ropes.

Upper Sheave

--

r~i -+

r: -

- I-- - - - -

i '--;-

'--- In

uu

Swivel Frame

Lower Sheave

'--

''

--=tA ,_

'

FAIR LEAD ASSEMBLY

FAIRLEAD SNUBBERS (two used) consist of a two pieced friction band anchored to frame structure and wrapped on a friction housing bolted to top of fairlead swivel bracket.

A bolt and heavy spring join the band halves. Adjust snubber, by turning connection bolt nuts, tight enough to stop any swinging of fairlead bracket at start or stop of machine rotation.

4-75

EM029421-0 (en-us)

/

\ Add Shims as Required with Wear of Thrust Washer.

Split Collar (271 lbs.)

To Remove Shaft, Remove Split Retainer and Pull Shaft

Hollow Shaft (4761bs.)

Thrust Washer

Bushing

VIEW AT A

Adjusting Nut

Swivel Frame (21680 lbs.)

To Remove Shaft, Remove Lockplates and Pull Shaft Solid Shaft (1066 lbs.)

Adjust Snubber by Tightening Nut Enough to Stop Swinging of Swivel Frame at Start or Stop of Machine Rotation.

VIEW 8-B

FAIR LEAD ASSEMBLY- SWIVEL FRAME

( 4-76

EM029421-0 (en-us)

Two DRAG ROPE LOWER SHEAVES are located in the swivel frames of the fairlead assembly. Each sheave is supported by a fixed shaft and rotates on two single row roller bearings. Bearings are assembled into the sheave with a machined spacer between the cones for accurate alignment and adjustment.

Bearings

Auto Lube Fitting

Wire Lock in Pairs (Typical Each End) Spacer Sleeve (124 lbs.)

Bearing Spacer (70 lbs.)

Sheave (10460 lbs.)

CAUTION: Secure Sheave before removing Shaft.

If the bearings must be replaced, remove the sheave assembly from the tri-structure by removing the lockplate and the retainer. Push shaft out from inside and lower the sheave to the ground.

4-77

EM029421-0 (en-us)

To REPLACE LOWER SHEAVE BEARINGS, the following procedure is applicable to each lower fairlead sheave and set of bearings. Remember to matchmark parts for assembly.

(

1. Chill and install bearing cups in sheave.

2. Assemble cone/roller assembly and clamp with jig J-14406-1 and tighten jig bolts until bearings bind slightly when rotated.

3. Measure distance between cones (gap "A") with inside micrometer at 3 places 120 degrees apart.

Calculate average dimension. Machine bearing spacer to calculated average dimension minus 0.002 to 0.004.

4.

Gap "A"

Remove jig and install sheave and bearings on shaft with machined spacer between bearings.

Note: Hand pack bearings with multi-purpose grease before assembly.

Jig

J-14406-1

5.

Reinstall bearing retainers.

6.

Lubricate shaft and bearing assembly thru shaft fitting.

NOTES:

( 4-78

EM029421-0 (en-us)

Two DRAG ROPE UPPER SHEAVES are located in the top of the fairlead assembly. Each sheave is supported by a fixed shaft and rotates on two single row roller bearings. Bearings are assembled into sheave with a machined spacer between the bearing cones for accurate alignment and adjustment. If bearing must be replaced, remove lockplates and spacer sleeve and push shaft out from inside. SECURE SHEAVE BEFORE REMOVING SHAFT. Bearing Spacer (39 lbs.)

Auto Lube Fitting

Shaft (2830 lbs.)

Wire Lock in Pairs (Typical Each End)

Spacer Sleeve (212 lbs.)

Lock Plate (165 lbs.)

Grease Retainer (158 lbs.)

Sheave (10010 lbs.)

4-79

Lock Plate (119 lbs.)

EM029421-0 (en-us)

To REPLACE UPPER SHEAVE BEARINGS, the following procedure is applicable to each upper fairlead sheave and set of bearings. Remember to matchmark parts for assembly.

(

1. Chill and install bearing cups in sheave.

2. Assemble cone/roller assembly and clamp with jig J-14106 and tighten jig bolts until bearings bind slightly when rotated.

3. Measure distance between cones (gap "A") with inside micrometer at 3 places 120 degrees apart.

Calculate average dimension. Machine bearing spacer to calculated average dimension minus 0.002 to 0.004.

4.

Remove jig and install sheave and bearings on shaft with machined spacer between bearings.

Note: Hand pack bearings with multi-purpose grease before assembly.

Jig J-14106

5. Reinstall bearing retainers.

6.

Lubricate shaft and bearing assembly thru shaft fitting.

NOTES:

( 4-80

EM029421-0 (en-us)

SECTION 5 ELECTRICAL MAINTENANCE INDEX

Page Care of D.C. Motors and Generators ............................ 5-1 Brush Installation .......................................... 5-1 Commutators ............................................. 5-2 Never Use Emery Cloth or Emery Paper ......................... 5-2 Proper lubrication ......................................... 5-3 Feeder Cable ............................................. 5-5 Power line Grounding Circuit ................................ 5-5 Electrical Troubleshooting: Preparation ......................................... 5-6 Investigation ........................................ 5-7 Performance ........................................ 5-9 Types of Failure ..................................... 5-9 Short Circuits ...................................... 5-10 Swing Control Pedals ...................................... 5-14 Main Collector Rings ...................................... 5-15 Auxiliary Collector Rings ................................... 5-16 Hoist/Drag limit Switches .................................. 5-16 Propel limit Switches ..................................... 5-17 Slack Rope limit Switch ................................... 5-18 Rotating Pinion limit Switch ................................ 5-19 Power Control Room (PCR) ................................. 5-20

EM029421-0 (en-us)

( \

WARNING DUE TO THE DANGERS INHERENT IN THE OPERATION OF ANY HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM SHOULD INCLUDE GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR AND RELATED RELAYS AND SWITCHGEAR.

A GROUND CONTINUITY CHECK

SYSTEM IS ALSO RECOMMENDED.

Marion provides (under separate cover} a separate book/manual from the electrical manufacturer in addition to the information supplied in this section.

FEEDER CABLE must contain a provision for a ground connection. Especially where 2300 volts and above are used. The power line end must attach (see paragraph on ground circuits} to a suitable permanent ground. The machine end must securely attach thru a bolted connection to ground machine frame. This provides a constant ground for the machine and electrical equipment. Failure to provide this adequate ground endangers works and equipment.

POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVER EMPHASIZED. Without a good grounding system, high voltage exists between the machine and ground. The portable cable and power lines supplying the machine must have a ground wire ample in capacity running parallel to the main wires over the entire distance from transformer to machine. A suitable grounding system must be used at the transformer.

Consult your local electric supplier for details.

(

EM029421-0 (en-us)

SECTION 5 ELECTRICAL MAINTENANCE

CARE OF D.C. MOTORS AND GENERATORS holds one watchguard- cleanliness. Keeping this equipment free of dirt, oil and grease is of prime concern. The operator generally recognizes and may correct the few common problems. Failure of this equipment is rare.

Serious problems require a competent electrician. In the case of poor commutation, where simple remedies can not solve the problem, consult the electrical equipment manufacturer.

BRUSHES with an excessive amount of arcing between brush and commutator when operating under normal loads and speeds need checked for the following: Are brushes sticking in holders?

Are brushes making fu II contact on commutator?

Are contact surfaces of the brushes clean?

NOTE: Determine this by removing the brush and looking at it's surface. The surface is smooth and polished where the brush rubs. Any portion not in contact has a rough, dark appearance. Loose brush holder studs throw brushes out of line and cause excessive arcing.

Here the brush rides on heel or toe out of normal commutating plane. Tighten brush holder into correct position to solve the problem. Loose brush holder yoke set screws permit the yoke to rotate and shift all the brushes. So they arc. Reposition the holder yoke and tighten. Another problem solved. Keep even spring pressure on ALL brushes. This exact pressure varies with unit type. Call the factory for specific information on your unit. The brush springs are set originally at one point. One may assume this pressure setting as correct and keep it exact when installing a new brush. This initial brush pressure should be the same for all brushes on any one motor or generator. Inspect all brushes regularly. Brushes worn beyond a point of good contact need replaced. Put in new one(s). Avoid allowing rapid brush wear. This resu Its in improper brush pressure and causes severe arcing. Excessive brush wear may even cause the pigtail to wear into the commutator proper. Check the brush springs.

Are they in their slots? When using fairly long brushes, it's a good practice to increase spring tension after brushes wear to make up for brush pressure loss. Use the same brush type as originally furnished with the unit when replacing. Serious problems occur when using an incorrect brush. A change in brushes sometimes improves a condition of poor commutation and severe arcing. First, consult manufacturer before making this change.

BRUSH INSTALLATION-Brush should properly fit holder or guide, to work up and down freely. Grind brush with 2/0 or 3/0 sandpaper until contact surface matches the commutator contour. Use the following procedure: Place brush in holder, release spring and insert sandpaper (wider than brush, rough side to brush) between brush and commutator. Exert

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full spring pressure on brush. Hold sandpaper close to commutator and draw it in direction of rotation. Then lift brush, push sandpaper back and repeat. Continue this operation until brush shapes to an even contact with commutator. Be sure to raise the brush before moving sandpaper back for the next stroke. DO NOT raise sandpaper when removing from commutator. This act generally ruins the fit on the brush. DO NOT install brushes and allow to fit by wear. This method usually causes arcing and scoring before brush wears in. After sanding brushes in, thoroughly clean aramture, commutator, risers and brush assembly with dry compressed air. Remove ALL carbon and copper cuttings. This prevents possible grounding or short circuiting. Failure to follow this proper cleaning procedure has resulted in costly shutdowns due to damaged armatures. After grinding brush, run in under light loads for a short period. This allows the surface to set or wear in before applying heavier loads. Install a complete set of brushes rather than replacing them one by one.

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COMMUTATORS frequently inspected by an electrician assures detection of surface faults in the early stages. This is important. Faults corrected early cost little in time loss or expense. Bar burning, high and low bars, high mica or flat spots become serious at an accelerating rate over time. When not seen and corrected early they often require a long shutdown.

A good commutator surface is highly polished. It shows a chocolate brown color. If the commutator is only slightly blackened due to arcing, the best cleaning procedure is the use of a piece of canvas wrapped around a wooden block. The canvas cleans the surface and does not scratch the copper. When excessive arcing takes place over a long time, a burned and blackened commutator results. In these severe cases, use a very fine sandpaper (2/0 or 3/0).

NEVER USE EMERY CLOTH OR EMERY PAPER. Emery conducts electricity. Serious injury to personnel and equipment results.

Shape a wooden block to commutator contour. Fold sandpaper around block and hold against commutator while motor or generator runs at no-load. Use a slow lateral movement of the block to avoid diagonal scratches. Undue amounts of sandpapering destroys the needed polished surface and results in increased brush wear. Use sandpaper as little as possible.

In most cases, polishing with canvas (see above) removes the blackening. One main objection to using sandpaper is that it rarely leaves bars properly grounded. On an unslotted commutator particularly with high mica, sandpaper tends to flatten the center of the bars.

Should the commutator become rough or pitted to a point where canvas and sandpaper cleaning does not remove bad spots, use a hand stone as needed. Sandpapering removes some slight spots, but not large flat ones. The effect merely broadens out the spots so they no longer show due to the flexibility of sandpaper. The stone smooths much better here.

The stone presents a rigid contact surface and may be held firmly in place while grinding.

Sanding or stoning destroys perfect brush contact. After polishing using either method, bring the unit to rest and remove carbon and copper dust with dry compressed air.

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Although hand stone grinding restores a true cylindrical surface, it does not remove extreme bad spots or Out of Round. A good commutator is within .0005 to .001 Out of Round when checked with a dial indicator. Out of Round is not caused by severe arcing and poor commutation, although it may cause these problems. Often Out of Round is caused by commutator changing shape due to heat and age. In extreme cases, remove the armature and turn or grind in a lathe. See that a qualified person does this work. After grinding, undercut the mica on the commutator. Some large commutators may be ground in the frame by a skilled person using the proper equipment. This avoids time loss in removal. Commutator speed while grinding is important here. This is why operation must be in the hands of an experienced person to prevent commutator damage by grinding at the wrong speed. After grinding, bring unit to rest and remove ALL carbon and copper dust with dry compressed air. Run-in brushes for a short period under very light load. This allows brushes to seat before applying heavier loads.

NEVER USE EMERY CLOTH OR EMERY PAPER. Emery conducts electricity. Serious injury to personnel and equipment results.

Commutation not corrected by simple remedies should be reported to the electrical equipment manufacturer.

PROPER LUBRICATION of bearings requires following this established procedure for all general conditions. First, we caution against over greasing. Of course, establish a HAPPY MEDIUM. Keep in mind that excess lube accumulates on armatures and windings causing electrical failure. Lubricate all bearings on new equipment according to the following chart for the first day of service. After that, every 6 months of actual running. Lubricate until a small amount appears at the shaft or starts out bottom drain hole (plug removed) of housing. After first day of service, lube with equipment at operating temperatures.

Shaft Diameter in inches

Amount of Lube in ounces

1/2 2

2-1/2

2 3

3

4-1/2

3-1/2

6

4-1/2 5 5-1/2

8 10 12-1/2 15-1/2

6

18

4

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NOTE: Many small motors use sealed bearings requiring no lube for 2 or 3 years. Add lube with units stopped and drain plug removed. After adding lube, run generator or motor with bottom plug removed for a few minutes to allow ALL excess lube to flow out. PLEASE REPLACE DRAIN PLUG. In most cases, the main hoist, drag and swing motors have no plug to remove. Surplus grease flows out in the pocket beneath bearing housing.

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On vertical and a few horizontal motors, remove the plug as done with generators. As mentioned in the 6 month lube procedure, these bottom plugs are removed before lubing to see that excess lube escapes. Probing with a clean wire assures the old grease has not hardened and blocked the passage. PLEASE REPLACE DRAIN PLUG. About once a year, or after 7500 operating hours; purge bearings by pumping enough lube thru bearing while running so new grease appears at shaft or bottom plug hole. As lube seeps out along shaft, wipe away. This is important. Finally, after 15 or 20 minutes of operation, thoroughly clean off shaft. New grease usually appears first at bottom hole, but it may be seen first at the shaft. PLEASE DO NOT FORGET THE DRAIN PLUG. Whenever possible, about once in 2 years, disassemble bearings and remove ALL old lube by thoroughly cleaning with light lube oil or petroleum solvent. Each time the bottom plug is removed, push a clean wire into the hole to check the lube is not hard and plugging the hole.

When repacking bearings with fresh grease, the housings or grease reservoirs should be filled from 1/2 to 2/3 full. An excessive amount of grease in the bearing will cause excessive bearing temperatures. See Table X. TABLE X BEARING LUBRICATION DATA

Frame Size

802 803 804 806 808 810 812 814 816 818 820 822 824 828

Min. (Grease Reservoir 1/2 Full) & Max. (Grease Reservoir 2/3 Full) of Grease at Each Bearing Cubic Inches Cubic Centimeters Ounces of of Grease of Grease Grease Grams 3Y2- 4Y2 57- 74 1%- 2% 50- 64 4 - 5% 66- 90 2 - 2% 50- 78 5 - 7 82- 115 2%- 3% 71- 99 6%- 9 107- 147 3%- 4% 92- 128 8%-11% 139- 188 4%- 5% 120- 163 13 -17% 213- 287 6%- 8% 184- 248 17 -23 279- 377 8%-11% 241- 326 20 -27 328- 442 10 -13% 284- 383 24 -32 393- 524 12 -16 340- 454 393- 541 12 -16% 24 -33 340- 468 29 -38 475- 623 14%-19 411- 539 34 -45 557- 737 17 -22% 482- 638 42 -51 688- 836 21 -25% 595- 723 1098-1278 67 -78 33%-39 950-1106

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Lubricate motor at standstill. If grease gun fittings are used, clean the fitting thoroughly before adding grease. The addition of grease for each lubrication should be limited to about 1/8 of the maximum grease tabulated in Table X. A shot of grease 1/4" diameter x 1" long weighs about .03 ounce. (A shot of grease 6mm in diameter x 33mm long weighs about 1 gram). Do Not Over Grease.

One measuring tablespoon equals approximately one ounce of grease. Use General Electric Company ball bearing grease D6A2C5 for their equipment. Use Westinghouse Electric grease 1449556 for their equipment.

CAUTION: DO NOT MIX GREASE NOT OF THE SAME BASE. In cold weather, when machine shuts down long enough to cool off, run hoist, drag and swing motors for warm up and allowing lube to flow before starting to dig. In extreme cold weather, motor bearings may be warmed with a radiant heater. As each set of motors warms up, run under light loads to maintain lube flow while the next set warms up.

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

POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVER EMPHASIZED. Without a good grounding system, high voltage exists between the machine and ground. The portable cable and power lines supplying the machine must have a ground wire ample in capacity running parallel to the main wires over the entire distance from transformer to machine. A suitable grounding system must be used at the transformer.

Consult your electric supplier or MPSD for details.

NOTES:

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ELECTRICAL TROUBLESHOOTINGA job well done generally comes from an established procedure, whether a written or mental process. A procedure carries thru the steps from PREPARATION to INVESTIGATION, then on to PERFORMANCE. The absence of this procedure only wastes time. Using a good one cuts down time and ends in a satisfactory job.

PREPARATION: Before efficient troubleshooting begins; a background knowledge of the system is necessary, particularly what happens and how it happens from start to finish.

Practically all electric machines use the same system, whether Amplidyne, Rototrols, Magamps, Amplistats, controlled rectifiers or contactors. That is, when the operator initiates a motion by moving the controller, he produces an output from the master switch. This output connects to the control system containing many simple or complex devices. The control system output feeds into the generator for amplifying and then on to the motor. So, the system simply is a master switch, control, generator and motor.

Knowing the general system is step one. what and how each functions, is needed.

Next, a fair understanding of components, and

Motors, for example, convert electric energy into mechanical energy. This is done thru armature current interaction and field flux. Before a motor can turn, enough of each of these quantities must exist to overcome the load. Generators are the opposite of motors since they convert mechanical energy into electric energy. Generators require BOTH rotation and field flux to produce output.

Control components often are quite complex. The Instruction Book for the electrical equipment discusses them completely and reading it is a must. However, one can learn to isolate components or part groups without knowing exactly how each device operates.

Another preparatory step requires the wiring diagrams and test data be at hand. If unavailable, contact Marion for a supply. An understanding of the drawing is needed and often redrawing helps this learning process. The test data helps greatly since the normal electrical readings are listed. A major deviation from this recorded data indicates trouble and often pinpoints the location. Test sheets include stall or maximum generator armature current, no-load or open circuit, generator and control exciter field currents and certain measurements made in the control circuit. Other data considered helpful may be obtained from the machine when operating under normal conditions. Each of the items is listed only to easily locate trouble. Learning to use the data speeds the process.

Take the diagrams to machine, locate all devices shown. In many cases, special test points, indicating lights or instruments offer troubleshooting aid. Locate the various test points without these aids (one might fail) to measure the various quantities listed on the test data sheet.

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Accurate, properly maintained test equipment, suitable for the quantities for measurement is needed also. a D.C. voltmeter for 125- 600 volts, a D.C. millivoltmeter for 600 millivolts, zero center meters preferred, a volt-ohm-milliamp meter or a multi-meter (example, Simpson 260), an A.C. voltmeter, unless multi-meter is accurate, a quality tachometer is often handy, and a 500 volt D.C. megger test insulation quickly.

Knowing the capabilities and limitations of each instrument helps keep repair and replacement costs reduced, since most test equipment suffers from the wrong connection rather than damage from dropping.

Now- get set to find the trouble.

INVESTIGATION: When trouble occurs, the operator is the "Expert Witness", so contact him first for answers to the following important questions: How many motions are affected?

Is motion dead or just retarded?

Is it intermittent or continuous?

Did trouble develop slowly or suddenly?

What happened just before the failure?

A complaint concerning POWER means different things to different people, so try to get specific answers to the following: Will machine lift as heavy a load as before?

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Has speed increased or decreased for light loads?

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Has speed increased or decreased for heavy loads?

Next, question other witnesses and determine what they saw or heard; getting every detail.

Then make a quick visual inspection of equipment for obvious things as flashover, smoke or other evidence of over-heating or broken components. (One electrician checked for hoursthen noticed the generator stopped.) Moral - look for the obvious.

After listening to witnesses and making the first inspection, stop and consider ALL the facts before proceeding. Valuable time is lost by going off quickly in the wrong direction. So, carefully examine the problem logically, using what you know about the system. Consider all the data collected. Do not make hasty decisions on what to use or what info to discard.

Give special value to obvious facts, easily confirmed (a stopped generator) and reserve opinion on contradictory facts.

Barring the obvious, you gain a direction from all this and knowledge of the system. For example, if no motion operates; look in circuits common to all motions, such as: D.C. exciter or A.C. circuits. Likewise, if one motion is normal in one direction; but not in the other, check the components for the separate directions. A few minutes spent analyzing here saves time spent in false, misled direction later.

Once a founded suspicion exists as to which set of components or circuits is faulty, select a starting point for tests that meets the following: You know approximate value expected here for test conditions; whether at stall, no-load, neutral, hoist, lower, etc.

No false indications exist, you've avoided points where reading is effected by a sneak circuit.

This point, logically, is in the suspected circuit.

Also, it allows checking as many circuits as possible at one time.

With proper instrument, measure at a selected point and compare to expected value. If measurement is correct, apparently all system parts leading to this point are correct. Trouble exists further down the line. With an incorrect reading, trouble probably lies further back toward start of the system.

Based on first test, proceed toward system start or end and seek expected reading. The trouble, of course, lies between points where correct and incorrect readings occur. In other words, the faulty stage has correct input, but incorrect output. Be positive the correct stage

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is located, rather than a false lead. Where possible, make tests under two different conditions (i.e., stall and no-load) to confirm conclusions.

Once faulty stage is located, determine the actual part that failed. Often an ohmmeter helps here, but may offer erroneous indications. If a semi-conductor, magnetic amplifier or other complex device is suspected, replace it rather than try to prove it bad by test. This saves time and tests just as well. This assumes that spares exist, as they should.

PERFORMANCE: Replace or repair faulty part, than prove this action correct by checking that system function properly. Many electricians feel the job complete with machine in operation. A good electrician determines the cause of failure, then takes necessary steps to prevent further failure. Cause may be the improper function of another part or circuit, improper use or overloading of a device, either by supplier or user; perhaps the effect of external conditions of dirt, moisture, temperature or normal life exceeded. A good electrician determines cause of failure and takes preventative steps.

TYPES OF FAILURES: The preceeding material, general in nature, allowed development of a procedure of troubleshooting for any problem. The following discusses certain failures in more detail.

Most failures are circuit opening, wire breaks, resistors or coils opening, faulty contacts, etc.

An open circuit's best feature is that current cannot flow, so the best check is for current flow.

Current measurements are difficult since opening a circuit and inserting the proper instrument is required. Generally, it's better to use Ohm's law and seek a voltage drop caused by the current using a voltmeter that connects easier.

Voltage measurements indicate an open circuit only if readings are properly understood.

Voltage across an open circuit generally is higher than expected. Special conditions such as a sneak circuit provide nearly normal voltage across an open circuit. The following is one example.

Assume a motor field is open. If normal voltage is almost the same as exciter voltage, the reading across the field wi II be almost identical whether field is open or not. Likewise, if several motor fields connect in parallel, voltage across the group changes little with one open field. While the voltage differs somewhat, this difference well could be attributed to a change in exciter voltage or an inaccurate meter. In these cases, find the trouble by measuring voltage across each field coil. This emphasizes an earlier point, use care in selecting a test point and eliminate confusing readings.

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Open circuits can usually be found using an ohmmeter and care in analyzing the measurements. In many cases, sneak circuits present the need to completely disconnect a device from other circuits.

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Open circuits generally cause complete or partial loss of output. In some cases, an open circuit can cause increased output. For example, if the current-limit field circuit opened; stall current exists higher than normal. Likewise, if voltage feedback opened; the no-load exists high.

Occasionally, open circuits cause effects very difficult to analyze. Consider an open armature circuit between the points where the current-limit signal taps off. This failure causes very low no-load voltage and very low stall current. Generally, these failures require a complete investigation. In this case mentioned, note th current-limit field current high at BOTH stall and no-load to point out the failure.

Measuring the current-limit signal voltage at stall gives a reading very close to normal, further indicating the need for proper understanding of measurements.

SHORT CIRCUITS, less common, are difficult to find; whether caused by external fault (foreign objects) or internal fault (turn insulation in coil failure). Capacitors and rectifiers generally fail due to shorting.

Characteristics are a lack of voltage across the part, and usually cause higher than normal currents that lead to failure in other devices.

Consider some typical cases. Shorted turns in a generator field coil give reduced output, the amount depending upon number of turns shorted. If coil resistance is quite low, determining that a few turns are shorted is difficult. Using a very accurate, low reading ohmmeter or voltmeter; take readings on ALL coils and compare accurately. Perhaps easier: apply A.C. voltage to all the coils connected in series and compare the voltage drop across each coil.

A shorted capacitor creates various effects. With capacitor used in an anti-hunt or stabilizing circuit, shorting the capacitor usually causes very low output that may be confused with other failure. A shorted capacitor in a filter circuit generally causes loss of filtered voltage and failure in other devices. For example, if current-limit bias voltage is obtained from rectified A.C., shorting a filter capacitor causes bias voltage loss, low stall current and possible failure of rectifiers and transformers.

Generally, capacitors are tested with an ohmmeter. Connecting a discharged capacitor across the ohmmeter indicates low resistance at first instant and high resistance once capacitor charges from the ohmmeter batteries.

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Rectifiers normally fail by shorting, but the effect depends upon the circuit. With rectifiers used to convert A.C. to D.C., shorting provides A.C. in output; detected by a multimeter on the output circuit. Shorted, blocked rectifiers allow current flow when the wrong polarity of voltage is detected.

Rectifier failure detection using the ohmmeter works, but the low voltage batteries in the meter do not always give a good test. Best results show up using the high resistance scale, but even this may not be conclusive.

The best test for rectifiers uses D.C. voltage at least 1/4th its rating. Connect a resistor in series with rectifier to limit current to a safe value. Connect resistor and rectifier across D.C. voltage, then read voltage across resistor. Reverse rectifier and measure resistor voltage. A good rectifier gives voltage across resistor with only one polarity.

Many other failures occur and often good intuition and ingenuity is needed to find them.

The trouble discussed thus far usually results in complete and permanent malfunction.

Perhaps more common and more difficult to find are intermittent failures resulting in only partial power loss. These trouble types distinguish a good troubleshooter from an average one.

Start as before, interviewing operator, oiler and witnesses. Try in questioning to determine the exact nature of trouble. When complaint indicates partial power loss, find the effect under various load conditions and determine the cause of this effect.

Often a cause for weakening may be determined in a similar manner as locating complete failure. Select a starting point and compare measurements taken against recorded data.

Compare honestly. A slight difference shows due to aging, temperature or an inaccurate instrument along with failure. Tests under one condition might not give a true problem indication. For example, tests at stall do not indicate no-load voltage is incorrect. Likewise, test for proper motor field voltage ONLY with controller (master switch) in proper position.

In addition, check that stall current or no-load voltage varies properly with master switch position, since trouble could be failure of master switch.

In locating trouble of the weakening kind, one needs to know the various devices functions used to augment or increase power under certain conditions. Master switch contacts fall in this device class. Motor field contactors increase field strength under certain conditions.

Conversely, current or voltage feedback circuits limit certain quantities to acceptable values.

Failures resulting in decreased or increased outputs generally come from failure in these supplementary circuits.

Help here comes from knowing the effects certain changes have on performance. Naturally,

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reducing stall current reduces motor torque so an equally heavy load cannot be lifted as before. A reduction in no-load voltage causes decreased speeds.

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A change in motor field strength offers various effects. A lower field voltage provides higher speed for light loads, but lower speed for heavy loads. Complete field loss gives very high speeds for light loads. Although this is uncommon, too strong a field creates low speed with light loads and probably high speed with heavy loads.

Many failures effect BOTH stall current and no-load voltage. A master switch failure generally effects BOTH. Fortunate and rare is the case of an intermittent problem occurring with the electrician aboard, so finding these requires a combination of skill and luck.

The starting procedure is the same. Gather needed info regarding effect on speeds and pulls.

Determine what the operator did just before the failure. Ask yourself, if any special weather or temperature conditions existed; how long did failure last in time and what was done to restart, etc. Study the system with this info and estimate the circuit(s) at fault. Look for the obvious first. Loose connections are commonplace.

As a last resort; simulate the fault. In other words, open the circuit felt to cause the trouble and see if it occurs again. CAUTION is the byword here since opening the wrong circuit could cause more damage than the failure. NEVER OPEN a critical circuit such as; currentlimit or voltage feedback unless it is positive the results will not prove damaging. Again, know your system.

As an example of simulated troubleshooting.

The complaint is of a sluggish swing motor. Although the troubleshooter rode the machine for several days, the trouble never re-occured. The operator remembered that the trouble occured only on hot days and he felt he'd know it if duplicated. The machine used threefield control. A weak motor field or weak generator field could cause sluggishness.

Simulating the trouble required first opening the motor field contactor, but to no avail.

Next, the self field contactor was opened and produced the same intermittent result. Investigation proved the contactor did not close in hot weather since coil resistance increased not allowing sufficient coil current to flow. Weakening spring tension solved the problem.

Unfortunately, some circuits do not check with the common instruments. These include anti-hunting or stabilizing circuits, plugging control circuits, rate circuits, etc. The use of these circuits is minimized, but often unavoidable on newer, sophisticated, fast response control systems. Failure of a plugging control circuit causes higher plugging currents and possibly bad commutation; but the operator generally notices a harder plug. Failure of sta-

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bilizing circuits causes motor oscillation, but not if critical frequency is too high. A high frequency oscillation causes a reduction in output (particularly stall current) if it is severe enough. When suspect of one of these circuits, the best one can do with the usual instruments is check circuit components. When these tests do not locate trouble, assistance may be required.

Previously discussed was the importance of starting tests at the right point. This is the logical one that checks the most components at one time. With failure in one motion, first check stall current. With correct stall current, assume master switch, control equipment and generator okay and trouble probably exists in motor.

With stall current incorrect, check generator field and then master switch. Suspecting the D.C. excitation system, check voltage on BOTH sides of fuses and then proceed to indicated direction. If A.C. system is the suspect, start at any point where three phase 220 or 440 volt supply is measured. If D.C. and A.C. voltmeter exist on machine, check them.

In conclusion, a good troubleshooter attack plan includes: Adequate preparation including: Understanding the system and components Availability of wiring diagrams and test data Quality test equipment designed for job Preliminary investigation to determine effect of fault Estimation of probable cause Testing for determining faulty part Correction of failure Preventative maintenance

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SWING CONTROL PEDALS, two located in front of operator, connect to the electric swing controller thru compound linkage. This linkage uses anti-friction bearings.

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A spring loaded plunger, mounted under the deck plate, returns the pedals to the neutral position. When pedal reaction becomes sluggish or binds; check here. Remove the plunger from the case, clean and lube with a small amount of MPG. Spacers, placed between spring and end caps, increase the spring tension.

Adjust pedal stop to strike floor plate at FULL left and FULL right swing. Adjust the pedal return lever arm by rotating the eccentric button on the lever arm so BOTH eccentric buttons contact the spring plunger in the neutral position. Once adjusted, weld button to lever arm.

Pedal Stops

Manual Lube Pin 2 places with MPG every 500 hours

Eccentric Buttons

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The MAIN COLLECTOR RINGS transmit incoming power from tub to rotating frame.

A

DANGER: ALWAYS DISCONNECT this incoming power at the source when servicing.

This assembly consists of four rings stacked with ceramic insulators secured to tub center pin. Location is in space over center journal below deck of rotating frame. The brushes attach to the outside case. Clean and inspect every 30 days.

Oilite Bushing (No lube required)

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Lube Fitting (Typ. 4 places) Manual Lube (MPG) every 12 months

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DANGER:

Remove power to rings and lock out before lubing ring bushings.

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AUXILIARY COLLECTOR RINGS are mounted at the top center of the main collector rings. Check for smooth operation. It is important that the collector rings and brushes are aligned properly and operate freely.

Cover

Drive Sleeve

HOIST/DRAG LIMIT SWITCHES- These switches are components of the Marion Protection System. The switches are the optical encoder type. The limit switch on the hoist drum is identical to the limit switch on the drag drum. Complete description, operation and calibration information is contained in the Marion Protection System Instruction Manual.

.-----1-- .10 Nominal Shim Gap Stub Shaft in Drum Assembly

Shims (Five Places) Optical Encoder

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Each hoist or drag limit switch (encoder) is mounted on a bracket which is attached to the drum shaft bearing retainer. Installation is accomplished as follows:

1. Mount encoder on bearing retainer with only solid shims in place.

2. With capscrews tight, check for +/-5 degree angular and +/-.010 parallel misalignment of encoder shaft with drum stub shaft. Add or subtract laminated shims to achieve proper alignment.

3.

Hand grind a flat surface on encoder drive shaft for coupling set screw.

4.

Install flexible coupling.

5.

Apply Loctite 242 to set screws.

6.

After adjusting coupling, lock with set screws.

The PROPEL LIMIT SWITCHES, left hand and right hand are connected to a hub in the end of each main propel shaft. These switches are components of the Marion Protection System. Complete description, operation and calibration information is contained in the Marion Protection System Instruction Manual.

Flexible Coupling

View Looking Forward Left Hand Shown- Right Hand Opposite

End of Propel Shaft

PROPEL LIMIT SWITCH (ENCODER)

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The SLACK ROPE LIMIT SWITCH operates to prevent excessive backlash when the hoist drum or drag drum rotates faster than the rope can be payed out.

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The slack rope strikes the switch trip wire which pulls the key from the limit switch. Actuation of the limit switch shuts down the affected motion and sets the brake. The Slack Rope Limit Light will illuminate on the operator's annunciator panel.

A limit switch and trip wire are located under both hoist drum and drag drum. Operation of the switch should be checked weekly.

NOTES: 1.

Lube all moving and sliding parts with MPG.

2.

Adjust trip wire for 1.00 inch sag measured at center of wire.

3.

t--r-- Switch Plunger

To adjust switch, remove key so mechanism is in activated position. Then slide switch up or down until plunger on switch is depressed enough to actuate switch.

Plunger must be depressed at least .05 inch to trip and has a permissable overall travel of .15 inch.

SLACK ROPE LIMIT SWITCH

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The ROTATING PINION LIMIT SWITCH operates when a rotating pinion drops down a short distance, signally the impending loss of the pinion. Actuation of the limit switch shuts down the swing motion and sets the swing brakes. The Swing Pinion Loss Light will illuminate on the operator's annunciator panel. Individual lights in the power control room will indicate which rotating pinion is affected.

Rotating Frame

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I I I Switch (Proximity Sensor)

Base Frame

C. Swing Pinion .12 Min .

.88 Max.

NOTES:

1. Adjust switch vertically to test and identify pick up point.

2.

Lower switch .25 to .50 below pick up point.

3.

Mount cover.

5-19

EM029421-0 (en-us)

Marion's POWER CONTROL ROOM (PCR) encloses electrical control components away from dirt, grease and dust. The segregation of control components into a room type module centralizes the responsibility of the electrician, thus improving control maintenance.

(

POWER CONTROL ROOM

The PCR is supplied with a constant source of clean filtered air under pressure affording the ideal environment for efficient operation of electrical components.

PCR is completely factory wired and only the input and output connections must be made during field erection.

( 5-20

EM029421-0 (en-us)

SECTION 6 COMPRESSED AIR SYSTEM AND COMPONENTS INDEX Page Air Compressors ........................................... 6-1 Inspect Drive Belt ........................................... 6-1 Anti-Freezer .............................................. 6-1 Magnet Valves ................· ............................ 6-2 Pressure Regulators ........................................ 6-2 Air Cylinder Valves ........................................ 5...:..2 Air Filters ................................................ 6-3 Air Valves ................................................ 6-3 Lubricators ............................................... 6-3 Quick Release Valve ........................................ 6-4 Air Filter System .......................................... 6-5 Charging Procedure- Pressurized Weldments .................... 6-6 Procedure When Loss of Air Pressure Occurs ..................... 6-6

EM029421-0 (en-us)

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EM029421-0 (en-us)

SECTION 6 COMPRESSED AIR SYSTEM AND COMPONENTS

The Marion air control is quite simple in operation. Reasonable care and maintenance ensures a long and trouble free life. Compressed air releases the hoist, drag, propel and swing brakes. It is piped to the auto-lube system also.

Air pressure provides a vital link in the safe operation of this machine. The operator MUST CONSTANTLY check the pressure gauge reading, located in operator cab. If at any time this pressure DROPS below 90 psi, SHUT DOWN and investigate the cause.

NEVER OPERATE THIS MACHINE WITHOUT FULL TANK PRESSURE.

Two AIR COMPRESSORS, located at rear of drag motors, are complete independent units.

The left compressor operates propel, swing, hoist and drag brakes. The right compressor supplies air to the automatic lubrication system. Should a compressor fail, close compressor valve atop tank and open globe valve at cross over between the compressors. This valve is normally closed.

INSPECT the belt drive often. Maintain PROPER belt tension which permits no more than 5/8" (15.875 mm) deflection of a single strand. ADJUST by moving the electric motor on the base. CHECK crankcase oil level DAI LV and keep at dipstick FULL mark. -Every 500 operational hours, DRAIN and FLUSH the crankcase. Look in Lubrication Charts for the proper NONDETERGENT oil to use. Cleantheaircleaneronceaweekordailyifconditions require.

ANTI-FREEZER, installed in air line, prevents icing and freeze-up of air system in severe weather. Introduced alcohol vapor mixes with water vapor in entering air. A bottom alcohol chamber and a top vapor chamber separate the unit. A central rod fits to a plug in the top. This rod, covered with a wick, carries alcohol up into the vapor chamber where it evaporates into the air stream. This in-line unit is non-adjustable.

MAl NTENANCE requires cleaning bowl and wick assembly with nonflammable solvent before freezing weather. Drain plug is in bottom. TURN OFF air compressor BEFORE checking or refilling. Vent the line pressure thru cut-out. Pressure not vented off escapes thru a small hole drilled in cap and vents out between cap and bowl. Due to this filler cap safety factor and

6-1

EM029421-0 (en-us)

to avoid overfilling; NEVER REFILL THRU WICK CAP. Use methyl alcohol only. (Permanent antifreeze types do not evaporate fast enough for good protection).

(

MAGNET VALVES need little or no maintenance. Dirt and scale cause a leaky valve sometimes. Try opening and closing it several times quickly by turning the small screw on top. Cleaning this way often avoids disassembly. If not, DISMANTLE, CLEAN, and REPLACE worn or damaged parts. Lube with a small amount of MPG. These electrically operated (on and off) valves are normally closed when de-energized. A spring loaded plunger shuts OFF air from supply to cylinder while the exhaust port from the cylinder to atmosphere is OPEN. Energizing the coil moves the plunger down, CLOSING the exhaust port and OPENING the port from supply to the brake release cylinder.

PRESSURE REGULATORS consist of a spring loaded diaphragm that moves a cone shaped seat which opens and closes, allowing air to pass thru the valve. A spring under this seat keeps it against the diaphragm. A T-handle on top screws in and out to adjust diaphragm spring tension.

Right (clockwise) increases and left (counterclockwise) decreases the tension; and the air pressure. When used in connection with clutches, the setting is at tank pressure low end to soften action and protect the clutch or parts.

NEVER USE MORE pressure than needed to handle a fully loaded bucket. When used elsewhere, a pressure gauge reading shows needed operating setting.

AIR CYLINDER VALVES actuate the brakes and are spring set; air released. A sleeve retains the spring and threads into the open cylinder end. A set screw locks this sleeve. Torepack cylinder, unlock set screw and turn out sleeve to release return spring tension. Discon-

( 6-2

EM029421-0 (en-us)

nect piston rod and air lines. Then, remove cylinder head and push the piston out until cup is exposed. Remove cap screw and lift off the packing cup. BEFORE reassembly of piston and NEW cup, coat ALL parts with graphite grease. READJUST brake after reassembly is complete.

AIR Fl LTERS placed in line so flow direction matches the arrow on body. They hang so moisture drains down into bowl. Solids and liquids are trapped here. Element removal is easy, when needed for cleaning in mild soap and water. Unscrew threaded bowl and element cartridge. Take apart cartridge by unscrewing lower baffle.

Remove element to service. Put back together and replace. Make certain ALL gaskets are properly placed. Compressed air drys elements quickly, if blown on inside. DO NOT use acetone, benzene, carbon tetrachloride, ethylene dichloride, gasoline, tau lene or the like. They damage plastic bowls AND storing them is not safe.

AIR VALVES are electrically controlled (some with manual override), pilot operated, noncompensating and normally closed. When valve fails to shut off or admit proper air volume, clean out dirt and scale that cause it to leak. Open and close valve manually several times. This attempt to clean usually postpones disassembly and cleaning. When this first-aid remedy fails; dismantle, clean and replace worn or damaged parts. All parts for normal maintenance and repairs are available in a repair kit.

The valve disassembles from machine without removing it from piping. Remove two socket head cap screws, then use flat screwdriver in body notch to lift from base. Remove pan head screw and cartridge retainer plate to remove cartridge. Clean parts completely and apply film of zinc base grease sparingly before rebuilding valve.

LUBRICATORS, place in line so flow matches arrow on body, deliver lube proportionate to air supply. Removing fill plug vents bowl pressure allowing a refill without air supply shutdown. Fill to visible bowl rim. Replace plug, seat firmly. This opens pressurizing valve. Extra torque is unneeded. An adjusting screw on top alters the flow; clockwise leans and counterclockwise richens.

Counting drops per minute in site dome helps adjust. (25 drops per minute equals 1 ounce per hour). Clean bowl in mild soap and water. DO NOT use any of the solvents mentioned in Air Filter above.

6-3

EM029421-0 (en-us)

QUICK RELEASE VALVE is located in the air line adjacent to each hoist and drag brake release cylinder. The air to cylinder must pass thru it. Full air pressure depresses a diaphragm CLOSING the exhaust port and OPENING the port from tank to cylinder. When supply pressure is shut off, a spring returns the diaphragm to normal position and OPENS the exhaust port. This allows pressure inside cylinder to escape and not pass back thru the control valve. No adjustment is needed. If valve fails to function properly, DISMANTLE and CLEAN. A repair kit contains needed replacement parts.

(

NOTES:

( 6-4

EM029421-0 (en-us)

AIR

FILTER

The entrance of dust and dirt into electrical equipment and other machinery causes extra wear to components. This is why ALL air entering the machinery house passes thru the filter house on top. Blowers create a slight pressure above the outside air. Leaving an access door open reduces this pressure. Dust and dirt generally enter. In operation, this slight pressurizing reverses any possible IN FLOW thru cable openings and personnel opening and CLOSING doors. This means ALL air drawn into the house is FILTERED. Thus protecting D.C, motors and generators, while providing longer life to commutators, carbon brushes and other machinery. Filtered air circulation reduces dust accumulation and results in lower operational temperatures of ALL equipment, including personnel.

Dirty air passes into the inlets located at the wide end of wedge shaped cells. Most air (about 90%) changes direction quickly and passes thru the narrow side passages. The dirt particles due to their greater mass, tend to continue straight into the bleed air duct. The dirt ladden bleed air (about 10%) continuously cleans the bleed air duct. Thus dirt particles and bleed air return outside. These self-cleaning filters require no regular maintenance.

A few suggestions may be helpful. For instance, keep air passages free of paper, leaves, wiping cloths, etc. This allows constant air flow. An inspection helps here. Check also for build-up of deposits on fi Iter blades. A light coat of dust is normal. Heavier build-up may require cleaning. Oil mist and similar vapors generally cause this problem. Remove the filters and scrub in soapy water. Please do not use solvents. The fi Iter vanes do not need oil. Believe it or not, it's been done.

6-5

SYSTEM AIR FILTER HOUSE ON TOP OF MACHINE

(Typical Five Places)

Blower

Filter

B NOTE: Manual lube motor every 500 hours with EMG. Pillow block bearings require MPG every 500 hours.

EM029421-0 (en-us)

(

CHARGING PROCEDURE- PRESSURIZED WELDMENTS 1.

Blow out air line from machine compressor before attaching to "Air Charging Apparatus" to remove any water accumulation.

2. With valve on "Air Charging Apparatus" closed, attach compressed air line.

3. Attach air supply hose leading from "Air Charging Apparatus" to weldment using quick disconnect coupling and charging equipment located on the weldment.

4.

Open air valve slowly and observe both gauges simultaneously for positive reading.

5.

Set pressure as determined by ambient temperature (see chart), close air valve, and separate quick disconnect coupling.

Ambient Temp. °F

Gauge Press.

PSI

Ambient Temp. °F

Gauge Press.

PSI

-30 -20 -10

9.5 10.0 10.5

60 68 80

14.5 14.5 14.5

0 10 20

11.0 11.5 12.5

90 100 110

14.5 14.5 14.5

30 40 50

13.0 13.5 14.0

120 130 140

14.5 14.5 14.5

PROCEDURE WHEN LOSS OF AIR PRESSURE OCCURS: 1.

Reset air pressure.

2.

Check all charging and monitoring hardware for leaks.

3.

Check weld seams over entire weldment for air leaks.

4.

Make any necessary repairs.

5.

Repeat charging procedure.

( \

6-6

EM029421-0 (en-us)

SECTION 7 ENGINEERING DATA INDEX

Page

Bushings ................................................ 7-1 Seals .................................................... 7-8 Gear Alignment Eccentrics (Draglines Only) ............... 7-9 Gear Backlash .......................................... 7-10 Eccentric Cartridges (Drag lines Only) .................... 7-14 Splines ................................................ 7-42 Anti-Friction Bearings .................................. 7-42 Shrink Fit Components .................................. 7-43 Cap Screws ............................................ 7-46 Wire Lock Cap Screws .................................. 7-47 Wire Rope Care ........................................ 7-49 Boom Strand Pendants ................................. 7-53 Repair Welding Procedures ............................. 7-56 0-Ring Guide .......................................... 7-70 Grid Couplings ......................................... 7-78 Falk Steelflex Couplings ................................ 7-83 Gear Couplings ......................................... 7-88 Motor-Generator Keyless Couplings (Draglines Only) .... 7-91

This section contains general information not specific to an individual machine. It is provided as general reference material for maintenance personnel.

Should additional specific data be required in these subject areas contact your Marion Service Representative.

EM029421-0 (en-us)

(

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EM029421-0 (en-us)

~ECTION

7

ENGINEERING DATA LIST OF TABLES

Page

Running Clearances for Bronze Bushings ( 1.0" thru 7.25) ............................... Table 1

7-2

Running Clearances for Bronze Bushings (7.75 thru 16.75) .............................. Table 1

7-3

Running Clearances for Bronze Bushings (17.0thru 24.25) .............................. Table 1

7-4

Running Clearances for Bronze Bushings (24.50thru 31.75) ............................. Table 1

7-5

Running Clearances for Bronze Bushings (32.0 thru 39.25) .............................. Table 1

7-6

Running Clearances for Bronze Bushings (39.50 thru 42.75) ............................. Table 1

7-7

Assembled Gear Backlash Tolerances ............ Table 2

7-12

Circular to Diametral Pitch Conversion ........... Table 3

7-13

Hub Advance and Temperature Chart ............ Table 4

7-45

Cap Screw Torque Values ....................... Table 5

7-47

Wire Rope Clip Spacing ......................... Table 6

7-53

0-Ring Modes of Failure ........................ Table 7

7-76

Decimal Equivalents-Inches to Millimeters ....... Table 8

7-76

Permissible Coupling Misalignment and End Float. Table 9

7-82

Coupling Installation Data ...................... Table 10

7-90

EM029421-0 (en-us)

(

EM029421-0 (en-us)

ENGINEERING DATA Design of Marion machines follows standards established by industry practices and procedures, material specifications and design/manufacturing disciplines developed by Marion. This section supplements the manual with additional information on maintenance practices and procedures. Some of this information may not apply to your specific machine.

BUSHINGS There are several types of bushings used on Marion machines. Two most common are the bronze sleeve bushing and the flange bushing. The sleeve type mounts in a machined bearing boss opening with a light press fit. A flange bushing rests in an opening and is held in place with a minimum of (4) four dowels. Dowel material is softer than bushing materials to prevent scoring of shafting over the life of the bushing.

Bushing service life depends on several factors. Various environmental conditions, lubricant types & maintenance practices will result in various replacement frequencies. Table 1 gives specification tolerances for the full range of shaft diameters. When running clearance exceeds the value of these tolerances by a factor of (3) three, REPLACE THE BUSHING. Bushing replacement requires disassembly of machinery shafting and gearing.

Removal of bushings may require the use of an air chisel to slit the bushing for removal. Use extreme care to avoid cutting or scoring the bearing boss. Once the bushing is removed CLEAN bearing boss thoroughly of metal burrs and debris, grease, and dirt.

A clean new bushing can be easily installed in a bore if it is cooled in a bath of dry ice and alcohol. This will shrink the outside diameter of the bushing allowing it to drop or slide freely into the bearing boss bore.

An alternate method installs the bushing using a long threaded rod, steel plates and a hollow center jack. Assemble items as shown in Figure 1. Lightly coat bushing O~D. and boss I.D. with high quality anti-scoring, extreme pressure, pressing oil. Then PULL the bushing in place. r

Pressing Oil Boss Steel Plate

Figure 1 Bushing Installation

7-1

E

EM029421-0 (en-us)

TABLE 1 RUNNING CLEARANCES FOR BRONZE BUSHINGS Inches (Millimeters) SHAFT Nominal Outside Diameter Diameter

I

\

Running Clearance

SHAFT Nominal Outside Diameter Diameter

Running Clearance

1 (25.4)

1.000-.999 (25.4-25.375)

.006-.010 (.152-.254)

4.25 (107.95)

4.250-4.248 ( 1 07.950-107.899)

.010-.019 (.254-.483)

1.25 (31.75)

1.250-1.249 (31.750-31.725)

.005-.010 (127-.254)

4.50 (114.3)

4.500-4.498 (114.300-114.249)

.010-.019 (.254-.483)

1.50 (38.10)

1.500-1.499 (38.100-38.075)

.008-.013 (.203-.330)

4.75 (120.65)

4.750-4.748 (120.650-120.599)

.014-.022 (.279-.559)

1.75 (44.45)

1.750-1.749 (44.450-44.425)

.008-.013 (.203-.330)

5.0 (127.0)

5.000-4.998 ( 127.000-126.949)

.011-.020 (.279-.508)

2.0 (50.8)

2.000-1.999 (50.800-50.775)

.007-.012 (.178-.305)

5.25 (133.35)

5.250-5.248 ( 133.350-133.299)

.011-.020 (.279-.508)

2.25 (57.15)

2.250-2.248 (57.150-57.099)

.006-.013 (.152-.330)

5.50 (139.7)

5.500-5.498 (139.700-139.649)

.012-.020 (.305-.508)

2.50 (63.5)

2.500-2.498 (63.500-63.449)

.006-.013 (.152-.330)

5.75 (146.05)

5.750-5.748 (146.650-145.999)

.012-.021 (.305-.533)

2.75 (69.85)

2.750-2.7 48 (69.850-69.799)

.008-.015 (.203-.381)

6.0 (152.40)

6. 000-5.998 (152.400-152.349)

.012-.021 (.305-.533)

3.0 (76.2)

3.000-2.998 (76.200-76.149)

.008-.015 (.203-.381)

6.25 (158.75)

6.250-6.248 ( 158.750-158.699)

.012-.021 (.305-.533)

3.25 (82.55)

3.250-3.248 (82.550-82.499)

.008-.015 (.203-.381)

6.50 (165.1 0)

6.500-6.498 ( 165.1 00-165.049)

.012-.021 (.305-.533)

3.50 (88.90)

3.500-3.498 (88.900-82.499)

.008-.015 (.203-.381)

6.75 (171.45)

6.750-6.748 ( 1 71 .450-1 71 .399)

.013-.022 (.330-.559)

3.75 (95.25)

3.750-3.748 (95.250-95.199)

.011-.019 (.279-.483)

7.0 (177.8)

7.000-6.998 (177.800-177.749)

.013-.022 (.330-.559)

4 (101.6)

4.000-3.998 .010-.011 (1 01.600-1 01.549) (.279-.483)

7.25 (184.15)

7.250-7.248 ( 184.150-184.099)

.013-.022 (.330-.559)

( 7-2

EM029421-0 (en-us)

TABLE 1 RUNNING CLEARANCE FOR BRONZE BUSHINGS Inches (Millimeters) Shaft Nominal Outside Diameter Diameter

Running Clearance

Shaft Nominal Outside Diameter Diameter

Running Clearance

7.75 (196.85)

7.750-7.748 .016-.024 ( 196.850-196.799) (.406-.61 0)

13 (330.2)

13.000-12.997 (330.200-330.124)

.020-.033 (.508-.838)

8.0 (203.2)

8.000-7.998 (203.2-203.149)

13.25 (336.55)

13.250-13.247 (336.550-336.474)

.020-.033 (.508-.838)

8.25 (209.55)

8.250-8.248 .015-.024 (209.550-209.499) (.381-.61 0)

13.50 (342.9)

13.500-13.497 (342.900-342.824)

.020-.033 (.508-.838)

8.50 (215.9)

8.500-8.498 .016-.025 (215.900-215.849) (.406-.635)

13.75 (349.25)

13.750-13.747 (349.250-349.174)

.021-.034 (.533-.864)

8.75 (222.25)

8.750-8.748 .016-.025 (222.250-222.199) ( .406-.635)

14.0 (355.6)

14.000-13.997 (355.600-355.524)

.022-.035 (.559-.889)

9.0 (228.6)

9.000-8.997 .016-.026 (288.600-228.524) (.406-.660)

14.5 (368.3)

14.500-14.497 (368.300-368.224)

.022-.035 (.559-.889)

9.25 (234.95)

9.250-9.24 7 .016-.026 (234.950-234.87 4) (.406-.660)

14.75 (374.65)

14.750-14.747 (374.650-374.574)

.023-.036 (.584-.914)

9.50 (214.3)

9.500-9.497 .016-.027 (241.300-241.224) (.406-.686)

15.0 (381.0)

15.000-14.997 (381.000-380.924)

.024-.036 (.61 0-.914)

9.75 (247.65)

9.750-9.747 (247.65-247.574)

.016-.027 (.406-.686)

15.25 (387.35)

15.250-15.247 (387.350-387.274)

.024-.036 (.610-.914)

10.0 (254.0)

10.000-9.997 .016-.027 (254.000-253.924) (.406-.686)

15.75 (400.05)

15.750-15.747 (400.050-399.97 4)

.024-.036 (.61 0-.914)

11.0 (279.4)

11 .000-1 0.997 .017-.028 (279.400-279.324) (.432-.711)

16.0 (406.4)

16.000-15.997 (406.400-406.324)

.026-.039 (.660-.991)

12.00 (304.8)

12.000-11.997 .017-.028 (304.800-304. 724) (.432-.711)

16.25 (412.75)

16.250-16.246 (412.750-412.648)

.026-.040 (.660-1.016)

12.75 (323.85)

12.750-12.747 .019-.030 (323.850-323. 77 4) (.483-.762)

16.75 (425.45)

16.750-16.746 (425.450-425.348)

.026-.040 (.660-1.016)

.015-.024 (.381-.61 0)

7-3

I

EM029421-0 (en-us)

TABLE 1 RUNNING CLEARANCES FOR BRONZE BUSHINGS Inches (Millimeters)

Shaft

Shaft Nominal Diameter

(

Outside Diameter

Running Clearance

Nominal Diameter

Outside Diameter

Running Clearance

17.0 (431.80)

17.000-16.996 (431 .80-431 .698)

.027-.041 ( .685-1 .041 )

20.75 (527.05)

20.750-20.746 (527.05-526.948)

.030-.044 (.762-1.117)

17.25 (438.15)

17.250-17.246 (438.15-438.048)

.027-.041 (.685-1.041)

21.0 (533.4)

21.000-20.996 (533.4-533.298)

.031-.045 (.787-1.143)

17.50 (444.5)

17.500-17.496 (444.5-444.398)

.027-.041 (.685-1.041)

21.25 (539.75)

21.250-21.246 (539.75-539.648)

.031-.045 (.787-1.143)

17.750 (450.85)

17.750-17.746 (450.85-450.7 48)

.027-.041 (.685-1.041)

21.50 (546.1)

21.500-21.496 (546.1-545.998)

18.0 (457.2)

18.000-17.996 (457.2-457.098)

.028-.042 (.071-1.066)

21.75 (552.45)

21.750-21.746 (552.45-552.348)

.031-.045 (.787-1.143)

18.25 (463.55)

18.250-18.246 (463.55-463.448)

.028-.042 (.071-1.066)

22.0 (558.8)

22.000-21.996 (558.8-558.698)

.033-.047 (.838-1.194)

18.50 (469.9)

18.500-18.496 (469.9-469.798)

.028-.042 (.071-1.066)

22.25 (565.15)

22.250-22.246 (565.15-565.048)

.033-.047 (.838-1.194)

18.75 (476.25)

18.750-18.746 (4 76.25-4 76.148)

.028-.042 (.071-1.066)

22.50 (571.5)

22.500-22.496 (571.5-571.398)

.033-.047 (.838-1.194)

19.0 (482.6)

19.000-18.996 (482.6-482 .498)

.028-.042 (.071-1.066)

22.75 (577.85)

22.750-22.746 (577.85-577.748)

.033-.047 (.838-1.194)

19.25 (488.95)

19.250-19.246 (488.95-488.848)

.028-.042 (.071-1.066)

23.0 (584.2)

23.000-22.996 (584.2-566.318)

.034-.048 (.863-1.219)

19.50 (495.3)

19.500-19.496 (495.3-495.198)

.028-.042 (.071-1.066)

23.25 (590.55)

23.250-23.246 (590.55-590.448)

.034-.048 (.863-1.219)

19.75 (501.65)

19.750-19.746 (501.65-501.548)

.028-.042 (.071-1.066)

23.50 (596.9)

23.500-23.496 (596.9-596.798)

.034-.049 (.863-1.244)

20.0 (508.0)

20.000-19.996 (508.0-507.898)

.030-.044 (.762-1.117)

23.75 (603.25)

23.750-23.746 (603.25-603.148)

.034-.049 (.863-1.244)

20.25 (514.35)

20.250-20.246 (514.35-514.248)

.030-.044 (.762-1.117)

24.0 (609.6)

24.000-23.996 (609.6-609.498)

.034-.049 (.863-1.244)

20.50 (520.7)

20.500-20.496 (520.7-520.598)

.030-.044 (.762-1.117)

24.25 (615.95)

24.250-24.245 (615.95-615.823)

.034-.050 (.863-1.270)

.031-.045 (.787-1.143)

( 7-4

EM029421-0 (en-us)

TABLE 1 RUNNING CLEARANCES FOR BRONZE BUSHINGS Inches (Millimeters} Shaft

Shaft Nominal Diameter

Outside Diameter

Running Clearance

Nominal Diameter

Outside Diameter

Running Clearance

24.50 (622.3)

24.500-24.495 (622.3-622.173)

.034-.050 (.863-1.270)

28.25 (717.55)

28.250-28.245 (717.55-717.423)

.039-.057 (.990-1.447)

24.75 (628.65)

24.750-24.745 (628.65-621.665)

.035-.052 ( .889-1 .320)

28.50 (723.9)

28.500-28.495 (723.9-723.773)

.039-.057 (.990-1.447)

25.0 (635.0)

25.000-24.995 (635.0-634.873)

.034-.052 (.863-1.320)

28.75 (730.25)

28.750-28.745 (730.25-730.123)

.039-.057 (.990-1.447)

25.25 (641.35)

25.250-25.245 (641.35-641.223)

.034-.052 (.863-1.320)

29.0 (736.6)

29.000-28.995 (736.6-736.473)

.041-.059 (1.041-1.498)

25.50 (647.7)

25.500-25.495 (647.7-647.573)

.034-.052 (.863-1.320)

29.25 (742.95)

29.250-29.245 (742.95-742.823)

.041-.059 (1.041-1.498)

25.75 (654.05)

25.750-25.745 (654.05-653.923)

.037-.055 (.939-1.397)

29.50 (749.3)

29.500-29.495 (749.3-749.173)

.041-.059 (1 ,041-1.498)

26.0 (660.4)

26.000-25.995 (660.4-660.273)

.037-.055 (.939-1.397)

29.75 (755.65)

29.750-29.745 (755.65-755.523)

.041-.059 (1.041-1.498)

26.25 (666.75)

26.250-26.245 (666.75-666.623)

.037-.055 (.939-1.397)

30.0 (762.0)

30.000-29.995 (762.0-761.873)

.041-.059 (1.041-1.498)

26.50 (673.1)

26.500-26.495 (673.1-672.973)

.037-.055 (.939-1.397)

30.25 (768.35)

30.250-30.245 (768.35-768.223)

.041-.059 (1.041-1.498)

26.75 (679.45)

26.750-26.745 (679.45-679.323)

.038-.056 (.965-1.422)

30.50 (774.7)

30.500-30.495 (774.7-774.573)

.042-.060 (1.066-1.524)

27.0 (685.8)

27.000-26.995 (685.8-685.673)

.038-.056 ( .965-1 .422)

30.75 (781.05)

30.750-30.745 (781.05-780.923)

.042-.060 (1.066-1.524)

27.25 (692.15)

27.250-27.245 (692.15-692.023)

.038-.056 (.965-1.422)

31.0 (787.4)

31 .000-30.995 (787.4-787.273)

.042-.060 (1.066-1.524)

27.50 (698.5)

27.500-27.495 (698.5-698.373)

.038-.056 (.965-1.422)

31.25 (793.75)

31.250-31.245 (793.75-793-623)

.042-.060 (1.066-1.524)

27.75 (704.85)

27.750-27.745 (704.85-704.723)

.039-.057 (.990-1.447)

31.50 (800.1)

31 .500-31 .495 (800.1-799.973)

.045-.064 ( 1 '143-1 .625)

28.0 (711.2)

28.000-27.995 (711.2-711.073)

.039-.057 (.990-1.447)

31.75 (806.45)

31.750-31.745 (806.45-806.323)

.045-.065 (1.143-1.651)

7-5

I

EM029421-0 (en-us)

TABLE 1 RUNNING CLEARANCES FOR BRONZE BUSHINGS Inches (Millimeters) Shaft

Shaft Nominal Diameter

(

Outside Diameter

Running Clearance

Nominal Diameter

Outside Diameter

Running Clearance

32 (812.8)

32.000-31.994 (812.8-812.647)

.043-.065 (1.092-1.651)

35.75 (908.05)

35.750-35.744 (908.05-907.897)

.048-.070 (1.219-1.778)

32.25 (819.15)

32.250-32.244 (819.15-818.99)

.043-.065 (1.092-1.651)

36.0 (914.4)

36.000-35.994 (914.4-914.247)

.048-.070 (1.219-1.778)

32.50 (825.5)

32.500-32.494 (825.5-825.347)

.044-.066 (1.117-1.676)

36.25 (920.75)

36.250-36.244 (920.75-920.597)

.048-.070 (1.219-1.778)

32.75 (831.85)

32.750-32.744 (831.85-831.697)

.044-.066 (1.117-1.676)

36.50 (927.1)

36.500-36.494 (927.1-926.947)

.048-.070 (1.219-1.778)

33.0 (838.2)

33.000-32.994 (838.2-838.047)

.044-.066 (1.117-1.676)

36.75 (933.45)

36.750-36.744 (933.45-933.297)

.049-.071 (1.244-1.803)

33.25 (844.55)

33.250-32.244 (844.55-818.997)

.044-.066 (1.117-1.676)

37.0 (939.8)

37.000-36.994 (939.8-939.647)

.049-.071 (1.244-1.803)

33.50 (850.9)

33.500-33.494 (850.9-850.747)

.046-.068 (1.168-1.727)

37.25 (946.15)

37.250-37.244 (946.15-945.997)

.049-.071 (1.244-1.803)

33.75 (857.25)

33.750-33.7 44 (857.25-857.097)

.046-.068 (1.168-1.727)

37.50 (952.5)

37.500-37.494 (952.5-952.347)

.049-.071 (1.244-1.803)

34.0 (863.6)

34.000-33.994 (863.6-863.447)

.046-.068 ( 1 .1 68-1 .7 2 7 )

37.75 (958.85)

37.750-37.744 (958.85-958.697)

.051-.073 ( 1 .295-1 .854)

34.25 (869.95)

34.250-34.244 (869.95-869.797)

.046-.068 (1.168-1.727)

38.0 (965.2)

38.000-37.994 (965.2-965.04 7)

.051-.073 ( 1 .295-1 .854)

34.50 (876.3)

34.500-34.494 (876.3-876.147)

.046-.068 (1.168-1.727)

38.25 (971.55)

38.250-38.244 (971.55-971.397)

.051-.073 ( 1 .295-1 .854)

34.75 (882.65)

34.750-34.744 (882.65-882.497)

.046-.068 ( 1 .168-1 .7 2 7 )

38.50 (977.9)

38.500-38.494 (977.9-977.747)

.051-.073 ( 1 .295-1 .854)

35.0 (889.0)

35.000-34.994 (889.0-888.847)

.046-.068 (1.168-1.727)

38.75 (984.25)

38.750-38.744 (984.25-984.097

.051-.073 ( 1 .295-1 .854)

35.25 (895.35)

35.250-35.244 (895.35-895.197)

.046-.068 (1.168-1.727)

39.0 (990.6)

39.000-38.994 (990.6-990.447)

.051-.073 ( 1 .295-1 .854)

35.50 (901.7)

35.500-35.494 (901.7-901.547)

.046-.068 (1.168-1.727)

39.25 (996.95)

39.250-39.244 (996.95-996.797)

.051-.073 (1.295-1.854)

( 7-6

EM029421-0 (en-us)

TABLE 1 RUNNING CLEARANCES FOR BRONZE BUSHINGS Inches (Millimeters) Shaft

Shaft Nominal Diameter 39.50 (1 003.3)

Outside Diameter 39.500-39.494 ( 1003.3-1003.14 7)

Running Clearance

Nominal Diameter

.052-.074 (1.320-1.879)

40.0 (1 016.0)

.052-.074 (1.320-1.879)

40.25 40.250-40.244 (1022.35) (1 022.35-1 022.197)

.052-.074 (1.320-1.879)

40.50 (1 028.7)

.052-.074 (1.320-1.879)

40.500-40.494 (1 028.7-1 028.547)

40.75 40.750-40.744 (1035.05) (1 035.05-1 034.897)

.054-.076 (1.371-1.930)

41.0 (1 041.4)

.054-.076 (1.371-1.930)

41 .000-40.994 (1 041.4-1 041.247)

41.25 41 .250-41 .244 (1047.75) (1 047.75-1 047.597)

.054-.076 ( 1.371-1.930)

41.50 (1 054.1)

.054-.076 (1.371-1.930)

41 .500-41 .494 (1 054.1-1 053.947)

41.75 41 .7 50-41 .7 44 (1060.45) ( 1060.45-1 060.297)

.055-.077 (1.397-1.955)

42.0 (1066.8)

.055-.077 (1.397-1.955)

42.000-41.994 (1 066.8-1 066.647)

42.25 42.250-42.244 (1073.15) (1 073.15-1 072.997)

.055-.077 (1.397-1.955)

42.50 (1 079.5)

.055-.077 (1.397-1.955)

42.500-42.494 (1 079.5-1 079.347)

42.75 42.750-42.744 (1085.85) (1 085.85-1 085.697)

Running Clearance

.051-.073 (1.295-1.854)

39.75 39.750-39.744 (1 009.65) (1 009.65-1990.497) 40 ..000-39.994 ( 1016.0-1015.847)

Outside Diameter

.056-.079 (1.422-2.006)

7-7

E

EM029421-0 (en-us)

SEALS Oil and grease seals are critical to machine availability. Careless storage, handling, removal and installation can contribute to reduced service life of machine components and higher cost of operation.

(

Seals come in all sizes, shapes and materials. Wherever possible Marion has specified the use of the most common solid molded element type seals for use on Marion machines.

All types of oil and grease seals have a limited shelf life. Store seals in a cool, dry location protected from direct sunlight. Keep in sealed containers or packaging until ready to use. Seals keep lubricant clean and contained in their respective housings, bearings or passageways. Always handle seals carefully to prevent exposure to nicks, bends or pinching. Do not wash them in solvents as some solvents may destroy properties of the seal.

SEAL INSTAllATION Solid molded seals are installed at time of manufacture with interference fit between seal and bore. This method of installation creates an oil tight fit. When partial disassembly of a machine component involves removal of solid molded seal before reassembly inspect it carefully for cuts, nicks, or cracking. Replace with a split seal if complete disassembly is inconvenient or with a new solid molded seal. Split seals, especially those made with interference fit at butt, also install with compression at the joint. Split seals used as substitutes for solid molded seals should be replaced at next major component overhaul.

A

CAUTION:

Do not cut a solid seal and reuse for a split seal.

Check shaft for scratches, burrs or surface roughness that may cut or score the seal lip. Be aware of sharp threads, keyways or splines over which the seal must travel. Protect seal lip by covering these interferences with tape.

Inspect the bore area for surface roughness, dirt or burrs. Remove and clean as required. The bore and shaft need .06 in ( 1.5 mm) chamfer to accommodate a leak free installation. If shaft or bore do not have chamfer carefully provide one by trimming inside flange of seal.

Determine the correct direction for lip installation and start the seal into the cavity by finger pressure, then tap evenly all around until seated or flush with the housing face. (Tap only on outer edge of seal with hammer on wood block.)

A double seal, installed back to back can be used to retain grease or oil plus be more effective in preventing egress of contaminants.

7-8

(

EM029421-0 (en-us)

Follow this installation procedure for split seals: Remove garter spring and separate at the hook and eye

0.,.

Open the seal ends sideways for installation on shaft as shown in Fig. 2 by moxiing the butt ends along the axis of the seal.

Wrong

Correct

Lubricate spring and install around shaft.

Connect ends and insert spring in lip groove with spring ends 90° away from butt joint.

A

CAUTION:

Figure 2 Split Seal Installation

Do not trim or cut ends of split seals or pull ends apart.

This will destroy seal.

Gear case seals used for all oil tight gear case assemblies require surface preparation on one side of case flanges with a 1/100 inch thick Form-a-Gasket :f:l:3 (Permatex Co.) coating. If using a manila paper gasket always replace with a new one, never reuse. Apply Form-a-Gasket :f:l:3 to both sides of the paper gasket. Tighten gear case cover bolts until seal material "squeezes out" at joint.

When surface finishes range up to 250 microinches a compression type gasket seal is recommended. This material (VELLUMOID available in standard thickness inches (mm) 1/64 (.397), 1/32 (.794) 1/16 (.063) and 1/8 (.125) should also be installed with Permatex applied to both sides.

GEAR ALIGNMENT ECCENTRICS (Draglines Only) There are two methods of sealing Marion gear alignment eccentrics. For eccentrics that are rigid (without a-ring seal) coat the surface of the eccentric with permatex liquid sealer FORM-A-GASKET No.3 (MPSD 134562-1) Coating of sealer should be brushed over the total surface· area of both contacting surface's according to the illustration and notes.

Gear Case

A. Coat this surface thoroughly with "Permatex" prior to assembly.

B. This contact surface may or may not receive a laminated shim depending on design. Coat this surface thoroughly prior to assembly and when shims are used coat surfaces on both sides of shim material.

7-9

a

c

Eccentric

Retainer Cap Bearing

D

Figure 3 Eccentric Cartridge

I

EM029421-0 (en-us)

C. Retainer cap sealing surface may or may not utilize shims depending on design. Eccentrics designed per detail shown would have shims installed at this location. Coat surfaces thoroughly on both sides of shim material.

(

D. When tapped holes are "thru holes" into interior of the gear case, apply Permatex thoroughly to both male and female thread prior to assembly.

0-Ring Seals

For movable (o-ring equipped) eccentric gear cases contact surfaces A and B are designed with o-ring seals for maintaining positive sealing characteristics while still being movable for adjusting purposes.

Gear Case

Contact Surface (A)

Eccentric Retainer Cap

When tapped threads are "thru holes into the interior of the gear case (C) apply Permatex thoroughly to both male and female threads prior to assembly.

Bearing

Contact Surface (B)

Retainer cap flange surface (D) may utilize shims depending on design at this location.

GEAR BACKLASH

Tapped Holes (C)

Figure 4 Eccentric Gear Case Sealing

All backlash values are given in the normal plane. Therefore, backlash checked with a dial indicator requires this device be set perpendicular to the helix of the teeth.

~ 90

THIS

~

I ... NOT THIS

~ Figure 5 NOTE: Backlash is the amount by which a tooth space exceeds the thickness of an engaging tooth measured on pitch circles.

7-10

(

EM029421-0 (en-us)

Required backlash for gears used on mining machines varies depending on value of diametral pitch. Table (2) gives assembled backlash values. These are measured in the plane of rotation.

NOTE:

Plane of Rotating Backlash is the actual clearance measured with a dial indicator between teeth on an assembled gear set after rotating to the point of closest engagement.

Backlash shall be checked four (4) places at 90° on all gears. No reading less than the minimum value indicated in Table 2 is acceptable. Individual readings may exceed table maximums however the average of the four (4) readings shall remain within the chart range.

Figure 6

When measuring normal backlash with a feeler gauge, values in Table 2 must be adjusted per the following: multiply the value in the table by the cosine of the helix angle.

Helix Angle

Cosine

30° 23°

.87 .92 .97

15°

With pinion torqued firmly to gear CHECK ttie contact and backlash side of teeth at the mesh point. DRAW a feeler gauge between teeth as shown in sketch. ADJUST pedestal until obtaining a near zero feeler gauge reading at CL and CR, and a near equal backlash (within recommended range) at BLand BR. TAKE measurements at four points on the gear, 90 degrees apart.

Establish all backlash values with load on the gear.

7-11

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EM029421-0 (en-us)

TABLE 2 ASSEMBLED GEAR BACKLASH TOLERANCES CENTER

DIAMETRIAL PITCH

DISTANCE

.5 (14)-.625(16)

.75 (19) .875 (22) 1.0 (25)

MIW

MIN 1

inches (millimeters)

.......a'

FROM

TO

20 (508) 40 (1016) 60 (1524) 80 (2032) 100 (2540)

20 (508) 40 (1016) 60 (1524) 80 (2032) 100 (2540) 120 (3048)

.040 (1) .040 (1) .044 (1.1) .044 (1.1)

MAX 2

.104 (2.64) .104 (2.64) .108 (2.74) .108 (2.74)

.026 (.66) .026 (.66) .028 (.71) .030 (.76) .036 (.91)

1.25 (32) 1.50 (38) 1.75 (44) MAX 2

.086 (2.18) .086 (2.18) .088 (2.24) .090 (2.29) .096 (2.44)

MIN 1

.020 (.51) .020 (.51) .020 (.51) .024 (.61) .028 (.71) .036 (.91)

2.0 (51) 2.5 (64)

MAX 2

.070 (1.78) .070 (1.78) .070 (1.78) .074 (1.88) .078 (1.98) .086 (2.18)

3.0 (76) 3.5 (89) 4.0 (101) MIN 1

MAX 2

MIN 1

MAX 2

.016 (.41) .016 (.41) .018 (.46) .024 (.61)

.062 (1.57) .010 (.25) .050 (1.27) .062 (1.57) .012 (.30) .052 (1.32) .064 (1.63) .070 (1.78)

!

!\) 1 When adjustment capabilities are designed into the open gear or pedestal mountings, backlash values should be selected between the minimum (MIN) and the average values as determined from the range indicated.

2 Maximum (MAX) values may increase by an additional .010 (.254mm) when an eccentric adjustment for alignment has been made in the plane of centers of an enclosed gear case.

/.-........,,

~

EM029421-0 (en-us)

The chart below establishes approximate conversions from circular pitch (C.P.) to diametral pitch (D.P.) for use with Table 2.

TABLE 3 CONVERSION CIRCULAR PITCH FROM INCHES (MILLIMETERS)

DIAMETRAL PITCH TO INCHES (MILLIMETERS)

6.0 (152.4)

.5 (12.7)

5.5 (139.7)

.5 (12.7)

5.0(127)

.625 (15.9)

4.5 (114.3)

.75 (19.0)

4.0 (101.6)

.75 (19.0)

3.5 (88.9)

.875 (22.2)

3.0 (76.2)

1.0 (25.4)

2.5 (63.5)

1.25 (31.8)

2.0 (50.8)

1.50 (38.i)

1.75 (44.5)

1.75 (44.5)

1.50 (38.1)

2.0 (50.8)

1.25 (31.8)

2.5 (63.5)

1.0 (25.4)

3.0 (76.2)

.875 (22.2)

3.5 (88.9)

.75 (19.0)

4.0(101.6)

7-13

E

EM029421-0 (en-us)

ECCENTRIC CARTRIDGES (Draglines Only) This section presents the theory of Eccentric Cartridges as used on Marion gear cases. A typical drag gear case is used to illustrate the principals and to present frequently encountered patterns with the appropriate eccentric adjustment to better the pattern.

The explanations apply to any eccentric (hoist, drag, swing, propel, crowd) and the reader should concentrate on the identification procedures used to predict shaft movement rather than trying to associate the eccentric with a particular location on the machine. After thoroughly familiarizing yourself with the theory and identification procedures a visit to the machine is in order.

Study each eccentric cartridge on your machine and mark the shaft movement for a given rotation of the eccentric.

7-14

(

EM029421-0 (en-us)

OBJECTIVE The "life" of any gear set is directly effected by the contact pattern between mating teeth. Therefore, it is desirable to obtain the best possible contact pattern.

However, allowable manufacturing tolerances and load deflections complicate attempts at controlling the contact pattern. Of course, it is cost prohibitive to completely eliminate the effects of tolerance and deflections. But, there is a method of optimizing the contact pattern.

If the pinion shaft (see typical gear set shown in Fig. 7) could be manipulated to optimize the contact pattern, the effects of tolerances and deflections could be minimized.

Figure 7 shows an eccentric cartridge on each end of the pinion shaft that provides a means of adjusting the shaft ends. Although each shaft end can only be moved along one axis, the axis on one end is perpendicular to axis on the other end. With two directional adjustments, the pinion shaft may be positioned in any attitude to optimize the contact pattern.

INTERMEDIATE GEAR

B".

BEARING ECCENTRIC BEARING HOUSING ECCENTRIC BEARING HOUSING

B~

<:A

PINION SHAFT

Figure 7

7-15

I

EM029421-0 (en-us)

( ECCENTRIC. CARTRIDGE

DIA.OF BRG. HOUSING

DIA.OF CASE BORE

Figure SA

Figure 8C

Figure 8

7-16

Figure 80

EM029421-0 (en-us)

THEORY

Eccentric cartridges are designed to provide one axis of movement for the shaft end and bearing. Refer to Figure 8A for a simplified but typical eccentric cartridge assembly where the shaft end is represented by the intersection of bearing centerline and shaft centerline.

Whenever the cartridge is rotated it revolves about the centerline of the case bore. Furthermore, every point of the cartridge rotates about the same centerline.

This includes the shaft end, which is represented by an end view of the shaft centerline.

Figure 88 is an enlarged end view of the relationship between the shaft centerline and the case bore centerline. The shaft end clearly rotates about the case bore centerline at a distance equal to the eccentricity of the cartridge.

If the cartridge is rotated a great amount, as shown in Figure 8C, the shaft end will move along on two axes instead of the required single axis movement. In fact the shaft end will always move on two axes.

However, as shown in Figure 80, by limiting cartridge rotation the amount of movement on one axis is small enough to ignore and movement is limited to a single axis for all practical purposes.

Notice that shaft end movement is measured relative to a reference centerline (Ref. ft ) that must be established on each shaft end. Movement of the shaft end is always perpendicular to the reference centerline.

7-17

I

EM029421-0 (en-us)

(

Figure 9B

Figure 9

7-18

EM029421-0 (en-us)

ORIENTATION Reference centerlines are selected relative to a plane defined by the pinion and gear axis of rotation as shown in Fig. 9A and 98. They are selected for the pinion shaft ends only. One reference centerline is in the plane (X-X) and the other is perpendicular (Y-Y) to the plane.

It does not matter if the reference centerlines were opposite from those selected in Fig. 98, as long as one reference centerline is in the plane and the other one is perpendicular to the plane.

From the previous section on eccentric cartridge theory, shaft end No. 1 will move perpendicular to the reference centerline, that is, along the X-X axis. This movement could also be described as moving shaft end No. 1 "into" or "out of" mesh. Obviously then, shaft end No.2 would move in a direction perpendicular to end No. 1 or along the Y-Y axis. This movement is often referred to as the "cross-bearing" adjustment.

OUT OF PLANE ADJUSTMENT When shaft end No.2 is moved along the Y-Y axis (Fig. 98) the adjustment is called out of plane because it seems to move out of the plane of interest.

OUT OF PARALLEL ADJUSTMENT When shaft end No. 1 is moved along the X-X axis (Fig. 98) the adjustment is called out of parallel because it seems to move the shafts out of parallel.

COMMENT It is recognized that both of the aforementioned adjustments seem to move the shafts out of parallel. However, to identify the direction of adjustment the "out of parallel" and "out of plane" nomenclature are used.

7-19

I

EM029421-0 (en-us)

Figure 10 ....,

V

(

,.-CENTERLINE CONTAINING "A" & "B"

<i. c

~ w a:

c

(!)

z

en_

0

:::1

m

0

w en

:I: (!)

oct

a:

0

m

PARTIAL KEYWAY INTERMEDIATE GEAR

BEARING

ECCENTRIC BEARING HOUSING

B~

PINION SHAFT

Figure 11

7-20

(

EM029421-0 (en-us)

TYPICAL ECCENTRIC CARTRIDGES

Fig. 10 is a typical eccentric cartridge that is utilized in Marion gear cases. Note the built-in eccentricity. Locate the centerline, to the case bore and the shaft bearing housing bore. It's the centerline through which the section is taken.

This centerline contains Points "A" and "8". Point "A" represents the shaft end and Point "8" represents the end view of case bore centerline. These are the very same Points "A" and "8" of Fig. 8. Therefore if this eccentric cartridge is rotated about Point "8", Point "A" will move perpendicular to the centerline that contained Points "A" and "8" prior to any movement.

After the two reference centerlines are selected for the gear case (review the section on orientation and Fig. 9) the eccentrics are installed with the centerline of the eccentric (that is common to Points "A" and "8") in-line with the reference centerline. These are factory set with very sensitive optical equipment.

Fig. 11 shows the cross-sections of both eccentrics as they are installed relative to the reference centerlines. Notice that the centerline containing Points "A" and "8" and the reference centerlines are in line.

It is entirely possible to determine the direction of shaft end movement (when the eccentric is rotated) by locating any one of several tell-tale signs. First, Fig. 10 shows a partial keyway on the bottom of the outside flange which indicates that the eccentric cartridge centerline contacting this partial keyway contains Points "A" and "8" and that Point "8" is closest to the keyways. Therefore if the cartridge is rotated clockwise the shaft end will move to the right as indicated in Fig. 10. Counterclockwise rotation produces movement in the opposite direction.

Another indicator is the "thick" and "thin" portions of the cartridge. The centerline containing Points "A" and "8" of the cartridge runs from "thin" to "thick" portions. The "thick" portion reveals the same information as the partial keyway.

This "thick" portion can be located by looking inside the case through the inspection openings.

Note: Figures 12 and 13 are shown on the next page. They point out two additional locations for the partial keyway. The partial keyway location for a given cartridge depends on the machine model and/or function. However, the partial keyway has the same meaning regardless of its location.

7-21

I

EM029421-0 (en-us)

Figure 12

(

PARTIAL KEYWAY

Figures 12 and 13 indicate other locations for the partial keyway rather than the location shown in Fig. 10. However, the partial keyway has the same meaning regardless of its location.

Figure 13

( PARTIAL KEYWAY

7-22

EM029421-0 (en-us)

CONTACT PATTERN The contact pattern between mating gear teeth may be established by any method that indicates the contact area. However, the reliability of the method must be considered. The following methods have provided excellent results when applied to Marion gearing.

Paste Type Layout Blue: Clean several teeth on the pinion and the mating teeth on the gear. Apply a "thin" coat of Prussian Blue to the pinion teeth. Roll the pinion thru mesh once so that each "blued" tooth contacts its mating gear tooth. Then roll the teeth back through mesh to the original starting position of the pinion. The Prussian blue will transfer from the pinion to the gear teeth when contact is made. Record the pattern (with sketches) and location of the pattern on the gear. Repeat until patterns are taken four places (every 90 degrees) on the gear. Adjust the pinion to provide the "best" (or optimum) pattern on the four gear locations. Repeat for each pinion contacting gear teeth. It helps to put clear scotch tape on the mating gear teeth. The bluing shows up better and the tape can be carefully removed and attached to paper thus providing an excellent record of the pattern.

Spray Blue: Clean as many teeth on the pinion as possible then spray on the layout blue and let it dry. Dry cycle (without digging for hoist and drag, slow speed for swing, and no lifting for propel) the machine several times. (About 5 min. worth.) Where contact is present the blueing will be rubbed off. This is by far the fastest method for checking patterns and hence the most popular.

A

CAUTION

The example used throughout this section is a drag case. The principals pertain to any Marion case that has eccentric cartridges. However, the eccentric cartridges may be opposite as shown in the example or a different case (such as swing, propel, or hoist case) and may look different. Merely locate the Reference Centerlines and the cartridge centerline containing points A and B and the direction of shaft end movement for a given rotation of the cartridge is determined.

If the pinion and gear are spur on single helical then block off one helix on the following pattern examples to change from double helical to spur or single helical.

The following section illustrates examples of contact patterns and the adjustments necessary to improve the pattern.

7-23

I

EM029421-0 (en-us)

(

INTERM,EDIATE GEAR

B"'

BEARING

ECCENTRIC BEARING HOUSING ECCENTRIC BEARING HOUSING

B~ ~A BEARING

PINION SHAFT

7-24

EM029421-0 (en-us)

TRUE AliGNMENT

NO CORRECTIVE ADJUSTMENT REQUIRED "OUT OF PARALLEL" ADJUSTMENT

VIEW A-A

["INTO" OR "OUT-OF" MESH] *POINT "A" IS OF PINION SHAFT **POINT "B" IS t OF ECCENTRIC BORE

t

I VIEW B-B

OUT OF PLANE ADJUSTMENT

["CROSS BEARING"]

7-25

EM029421-0 (en-us)

(

B"'

INTERMEDIATE GEAR

ECCENTRIC BEARING HOUSING

BEARING ECCENTRIC BEARING HOUSING

B~

PINION SHAFT

( 7-26

EM029421-0 (en-us)

MISALIGNMENT OF PINION SHAFT OUT OF PARALLELISM

CORRECTIVE ADJUSTMENT

VIEW A-A ADJUST ECCENTRIC IN COUNTERCLOCKWISE DIRECTION.

I VIEW 8-8 NO ADJUSTMENT REQUIRED.

7-27

EM029421-0 (en-us)

INTERMEDIATE GEAR

B~ BEARING ECCENTRIC BEARING HOUSING ECCENTRIC BEARING HOUSING

B~

PINION SHAFT

( 7-28

EM029421-0 (en-us)

MISALIGNMENT OF PINION SHAFT OUT OF PARALLELISM

CORRECTIVE ADJUSTMENT

VIEW A-A ADJUST ECCENTRIC IN CLOCKWISE DIRECTION.

I VIEW B-8 NO ADJUSTMENT REQUIRED.

7-29

EM029421-0 (en-us)

(

INTERMEDIATE GEAR

B~ BEARING ECCENTRIC BEARING HOUSING ECCENTRIC BEARING HOUSING

B~

PINION SHAFT

( \

7-30

EM029421-0 (en-us)

MISALIGNMENT OF PINION SHAFT OUT OF PLANE

nn

CORRECTIVE ADJUSTMENT

VIEW A-A NO ADJUSTMENT REQUIRED.

I VIEW B-8 ADJUST ECCENTRIC IN COUNTER CLOCKWISE DIRECTION.

7-31

EM029421-0 (en-us)

(

INTERMEDIATE GEAR

B~ BEARING ECCENTRIC BEARING HOUSING

ECCENTRIC BEARING HOUSING

B') ~A BEARING

PINION SHAFT

( 7-32

EM029421-0 (en-us)

(

MISALIGNMENT OF PINION SHAFT OUT OF PLANE

CORRECTIVE ADJUSTMENT

VIEW A-A NO ADJUSTMENT REQUIRED.

I VIEW 8-8 ADJUST ECCENTRIC IN CLOCKWISE DIRECTION.

7-33

EM029421-0 (en-us)

(

INTERMEDIATE GEAR

B~ BEARING ECCENTRIC BEARING HOUSING ECCENTRIC BEARING HOUSING

'

B~

PINION SHAFT

( 7-34

EM029421-0 (en-us)

MISALIGNMENT OF PINION SHAFT OUT OF PARALLELISM & PLANE

CORRECTIVE ADJUSTMENT

VIEW A-A ADJUST ECCENTRIC IN CLOCKWISE DIRECTION.

VIEW B-B ADJUST ECCENTRIC IN CLOCKWISE DIRECTION.

7-35

EM029421-0 (en-us)

(

INTERMEDIATE GEAR

B~ BEARING ECCENTRIC BEARING HOUSING

ECCENTRIC BEARING HOUSING

B')

PINION SHAFT

( 7-36

EM029421-0 (en-us)

(

MISALIGNMENT OF PINION SHAFT OUT OF PARALLELISM & PLANE

CORRECTIVE ADJUSTMENT

VIEW A-A ADJUST ECCENTRIC IN COUNTERCLOCKWISE DIRECTION.

I VIEW 8-B ADJUST ECCENTRIC IN CLOCKWISE DIRECTION.

7-37

EM029421-0 (en-us)

(

INTERMEDIATE GEAR

B~ BEARING ECCENTRIC BEARING HOUSING

~ECCENTRIC BEARING

I

HOUSING

B~

PINION SHAFT

( 7-38

EM029421-0 (en-us)

MISALIGNMENT OF PINION SHAFT OUT OF PARALLELISM & PLANE

CORRECTIVE ADJUSTMENT

VIEW A-A ADJUST ECCENTRIC IN CLOCKWISE DIRECTION.

I VIEW 8-8 ADJUST ECCENTRIC IN COUNTERCLOCKWISE DIRECTION.

7-39

EM029421-0 (en-us)

(

INTERMEDIATE GEAR

B~ BEARING ECCENTRIC BEARING HOUSING ECCENTRIC BEARING HOUSING

8~

PINION SHAFT

7-40

EM029421-0 (en-us)

MISALIGNMENT OF PINION SHAFT OUT OF PARALLELISM & PLANE

CORRECTIVE ADJUSTMENT

VIEW A-A ADJUST ECCENTRIC IN COUNTERCLOCKWISE DIRECTION.

VIEW 8-8 ADJUST ECCENTRIC IN COUNTERCLOCKWISE DIRECTION.

7-41

EM029421-0 (en-us)

SPLINES Cured splines disassemble by breaking the bond with puller, press or hydraulic jack and then removing. Temperatures at least 400 degrees F. (204 degrees C.) (NOT over 650 degrees F. or 343 degrees C.) weaken the bond also. Apply pressure and remove while hot.

(

INVOLUTE SPLINE ASSEMBlY Involute spline assemblies permanent fit with adhesive as indicated by Class #2 design. The approved adhesive is Loctite CVV 82 (key fit). Standard parts joined with involute splines assemble with a liquid adhesive that hardens when confined in the absence of air.

Anti-friction bearings installation on a shaft requires an interference fit, assemble BEST by shrinking the inner race onto the shaft. This means creating a difference in temperature between shaft and the inner race. Heating the bearing is easier than cooling the shaft. Heat the bearing in a suitable oven or other means of dry heat.

NOTE:

A

DO NOT APPLY HEAT DIRECTLY TO THE BEARING. Warning:

Do not use a water or oil bath to heat bearings.

DO NOT HEAT ABOVE 250 degrees F.

( 7-42

EM029421-0 (en-us)

SHRINK FIT COMPONENTS Instructions for installation and removal of shrink fit components with tapered bores: INSTALLATION 1. Thoroughly clean the seating surface on the shaft and the tapered bore of the component using a recommended standard safety solvent such as the "Stoddard" type solvents,and wipe dry with a cloth.

2. Remove any scoring or high spots on either part and check with "Bluing" by spotting the cold component on the shaft by hand to obtain at least 75% fit.

In case you do not have 75% fit the component should be scraped until desired fit is indicated by repeating bluing and cold fitting.

3. Break all sharp edges of the key with a fine file so there will be approximately .015 inch radius at each edge. Fit the key to the shaft, taking care to avoid upsetting the metal of the shaft next to the key. The key should be tight in the shaft but not so tight that it must be hammered in place.

4. The cold component must be tried on the shaft to make certain it does not bind on the key.

5. Mount the component cold on the shaft and snap it into position by hand.

6. Measure the cold position using a micrometer depth gauge as indicated in the detail. Record the measurement. Mark where the depth gauge was resting so measurements can be made from the same position after the component has been mounted.

7. Remove the component from the shaft and thoroughly clean all bluing marks from the bore and shaft. Remove or protect seals or other items that may be damaged by heat.

8. With the component removed, heat in a suitable oven or other means of dry heat. Control the temperature as directed using values indicated in the table.

A. Do not use oil or water to heat component.

B. Component temperature must never exceed 350 degrees F. (177 degrees C.).

7-43

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EM029421-0 (en-us)

C. The temperature differentials indicated in the table represents calculated values to obtain the listed hub advance. The values represent the number of degrees (Fahrenheit or Celsius) difference required between the shaft and the component at the time of assembly. For example, if the shaft is 77 degrees F. (25 degrees C.) and the temperature difference in the table is 155 degrees F. (86 degrees C.) heat the component to 232 degrees F. ( 111 degrees C.) for mounting.

D. To check the temperature of the component, use a Fahrenheit or Celsius thermometer by placing putty over the bulb and holding it against the hub. Heat component a few degrees above the desired temperature before removing it from the oven.

9. After the component has been removed from the oven, wait a few minutes until the bore has cooled to the temperature required, remove the thermometer and quickly mount as described.

10. After making sure the bore is clean, quickly locate the component in the same angular position on the shaft as when cold. When nearly engaged with the taper fit, but not actually in contact, snap it forcibly into place with a quick push. It is important that the hot component be instantly snapped into position before it has cooled appreciably. Otherwise, it will immediately freeze to the shaft and cannot be adjusted further.

11. Check the hot shrunk-on position of the component on the shaft using the micrometer depth gauge as before.

A. The actual advance is the difference between the depth gauge reading at the hot and cold positions. To control the stresses in the component the advance must be within the limits specified in the table.

NOTE:

If the advance is not within the limits given, the component should be pulled and remounted.

12. After the component has been properly shrunk on the shaft, assemble the lock washer and nut or other means of locking.

13. When shoulder nuts are used, make certain the shoulder does not bottom before the main body of the nut tightens on the locking plate. In case the shoulder on the nut bottoms before tightening on the locking plate, the nut should be removed and the shoulder ground or machined off so clearance is available.

14. After it is certain that the nut is securely tight, turn up the locking plate on at least two faces of the nut.

7-44

, (

EM029421-0 (en-us)

A. It should be kept in mind that the component fit on the shaft and the fit on the key are important points in doing a good job of holding the component on the shaft. The locking plate simply serves to hold the nut on the shaft. With the correct fit between the tapered bore and shaft there is no load on the nut and locking plate.

REMOVAL 1. When removing the component from a motor armature, always use a suitable puller to avoid causing damage to either the component, motor frame, bearings or armature shaft. Do not heat the component before pulling and do not use wedges between the component and the bearing cap. In order to prevent damage to anti-friction bearings, avoid the use of sledge hammer on the puller.

SHRINK FIT MOUNTING DATA

Micrometer depth gauge being used to measure component advance. Note that lineup marks used to locate gauge, component and shaft are in identical positions for "Hot" or "Cold" measurement.

Micrometer

Figure 14

TABLE 4 HUB ADVANCE AND TEMPERATURE CHART Motor Frame Size

w

GE

Motor Shalt Diameter

IN

(MM)

HUB Advance

IN

(MM)

Temperature Difference Deg[FJ

Deg(C)

802

802

1.75 (44.45)

.019-.029 (.483-.737)

230

128

803

803

2.0 (50.80)

.023-.033 (.584-.838)

230

128

804

804

2.0 (50.80)

.023-.033 (.584-.838)

230

128

806

806

2.5 (63.50)

.028-.038 (.711-.965)

215

119

808

808

3.0 (76.20)

.028-.038 (.111-965)

190

106

810

810

3.25 (82.55)

.033-.043 (.584-1.092)

190

106

812

812

3.62 (91.95)

.033-.043 ( .584-1.092)

170

94

814

814

4.25 (107.95)

.038-.048 (.711-1.219)

165

92

816

816

4.62 (117.35)

.038-.048 (.711-7.279)

155

86

818

818

5.0 (127.0)

.043-.053 (1.092-1.346)

155

86

720

820

5.88 (149.35)

.043-.053 (1.092-1.346)

135

75

722

822

6.25 (158.75)

.047-.057 (1.194-1.448)

135

75

724

824

7.0(177.80)

.047-.057 (1.194-1.448)

120

67

828

8.5 (215.90)

.052-.062 (1.327-1.575)

110

61

-"

7-45

EM029421-0 (en-us)

CAP SCREW (BOlT) GRADE. The grade classification of a cap screw (bolt) is identified by the marks on the head as shown below:

Grade 5

Grade 8 Figure 15 Cap Screw Grade Markings

Use the SAME GRADE washer and nut as bolt.

Selection of the proper method TORQUE VS. TURN-OF-NUT depends on certain conditions. Use one of the two methods described based on the specific application: TURN-OF-NUT METHOD Small quantities involved Inconsistent thread conditions and fits Usually exceeds 2,000 foot pounds (2712 Nm) Torque measuring equipment impractical for assembly TORQUE METHOD Large quantities involved Consistent thread conditions and fits Usually less than 2,000 foot pounds (2712 Nm) Torque measuring equipment available at assembly TURN-OF-NUT METHOD: Install bolts and tighten to SNUG FIT. This means tight with a hand tool or if using impact wrench, when the drive stops and racheting starts.

Use crayon, chalk or paint to mark nut at side and clamped surface to indicate the SNUG FIT position. Mark impact drive socket when used.

Hold bolt head with wrench and using a heavy duty impact, hand wrench and heavy hammer (or sensible alternate method); advance nut one-half-turn.

Tighten nuts progressively from fixed edge to free edge. This achieves tension and prevents loosening under most severe conditions.

7-46

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EM029421-0 (en-us)

TORQUE METHOD: The recommended torque values listed in the following TABLE apply to non-plated fasteners as received from manufacturer with no special lubricants applied.

Also, the values are based on "Unified Course" threads.

TABLE 5 TORQUE VALUES

Dia. 5/16 3/8 7/16 1/2 5/8 3/4

1 1-1/4 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3

(in.)

-.31 -.38 -.44 -.50 -.62 -.75 -1.00 -1.25 -1.50 -1.75 -2.00 -2.25 -2.50 -2.75 -3.00

Grade 8 & Socket Hd.

Grade 5

Fastener (MM)

7.87 9.65 11.18 12.70 15.75 19.05 25.40 31.75 38.10 44.45 50.80 57.15 63.50 69.85 76.20

Ft.-Lb. 17 30 48 75 150 265 645 1,200 1,950 2,285 3,440 5,030 6,875 9,320 12,315

Nm 23 41 65 102 203 359 875 1,519 2,644 3,098 4,664 6,820 9,322 12,637 16,698

Ft.-Lb. 24 43 70 105 210 375 905 1,820 3,160 4,990 7,500 10.970 15,000 17,800 23,510

Nm 33 58 95 142 285 509 1,227 2,468 4,285 6,766 10,170 14,875 20,339 24,136 31,878

WIRE LOCKING CAP SCREWS Wire locking of cap screws is used when maximum lock assurance is required when periodic visual inspection is not possible.

Illustrations in the Figure 16 show recommended wire lock methods for various right hand thread cap screw patterns. For patterns not shown, wire lock screws "in pairs". For odd numbered patterns, wire lock remaining "three" cap screws together.

7-47

I

EM029421-0 (en-us)

~~

~)--

(

---{---+--\

H".

-{---+\

I

I

.

I

M--

--1---+---

~-

Figure 16 Wire Lock Patterns Use 14 gauge soft annealed lockwire. Thread wire through screw head so tightening stress on the wire will exert tightening torque on the direction of cap screw thread. (Illustrations show lock wire threadinq_ for right hand threaded cap screws. Reverse lock wire patterns shown for left hand cap screws.)

( \

7-48 '

EM029421-0 (en-us)

WIRE ROPE CARE Wire rope manufacture uses the finest material available. Wire rope is more vulnerable to abuse and neglect than any other component on this machine. By comparison to other industrial applications, wire rope on mining equipment remains relatively short lived and hence considered an expendable item.

Replacement of hoist and support ropes represents a sizeable investment; so every effort must be applied to extend the useful life of ropes.

The vulnerability to abuse and mishandling may cause a new rope permanent damage during installation. Improper removal from reel or coil often causes kinks. Pulling on rope until loop radius reduces to point where wire rope bends beyond the metal elastic limit creates these kinks. Pulling rope over a small sized sheave causes a kink also. Even when kink appears straightened, the strand damage and weakness remains.

Abrasion or nicks caused by pulling a rope over sharp objects weakens the rope. Wire rope needs protection from possible damage when a winch or lifting device attaches to strands forming a dogleg bend in the rope.

A coil of rope correctly unwound is rolled, (like ahoop), along a smooth surface and away from the rope end.

When removing rope from reel, place a heavy shaft or pipe thru reel center and raise until reel turns freely. Allow this free turning as rope end is carried straight away from the reel. Use a wedge block or plank against the flange to act as a brake. Whenever possible, transfer rope directly from reel to drum. (See sketch). In case of overwind, transfer rope from top of reel to top of drum. Likewise, for underwind; transfer rope from bottom of reel to bottom of drum. Avoid any methods where a reverse bend in rope might occur.

WRONG

RIGHT

Figure 17 Rope Coiling Procedure A good operator and maintenance crew develops the habit of watching ropes during work cycle to determine any damage in rope appearance caused by accident, broken wires, etc. Inspection determines, by careful measurement and comparison with a new rope, any loss in rope diameter. This loss at isolated spots indicates core failure. Where core failure occurs, the rope collapses and lay length (one full strand wrap) increases.

Diameter loss over a large area indicates normal outer wire wear. Wires wear more rapidly on a new rope due to minimum surface contact of each wire. As these wires wear, they present a flattened surface and the rate of normal wear decreases.

7-49

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EM029421-0 (en-us)

Determine the cause of outer wire breal<s by examining the break.

Tension breaks show a cup and cone effect at the break. This is caused by overload, shock load, jerking a load or catching a falling load.

(

Careless operational load handling.

Fatigue break showing a square end break with granular metal appearance.

Repeated bending over sheave causes fatigue or the sway and vibration at dead end anchor and static sheave.

A shear break indicated by a smooth, twisted break generally comes from external damage (nicks or kinks) in the rope.

Several outer wire breaks at isolated areas along rope length cause little concern. Concentrated breaks at a single location indicate severe rope damage.

Retire this rope.

External corrosion indicated by rust, scales or pitting on rope surface remains out in the open. Internal corrosion may appear as pitting in strand valley or rust and scale working out from under strands. Outside wire or strands appear slack or seem to stand out from inner portion with severe corrosion. Under a load this rope shows a loss in diameter.

Internal wear or core fatigue indications emulate those of severe corrosion.

Wire or strands appear slack and noticeable loss in diameter occurs under load.

Internal wear often results from faulty equipment (tight sheave groove, etc.) in a local area.

Rope retirement from service requires a decision based upon a combination of factors.

Inspection determines the abrasive wear effect on outer wires. Percentage of rope area intact indicates rope strength percentage remaining.

The number of broken wires contained within one lay (one full strand wrap) evaluates remaining rope strength to some degree.

No reliable means of determining corrosive effect and internal wear exists.

Good operating conditions and effective lubrication keeps these factors to a minimum.

Study the entire rope to determine the section suffering the most severe deterioration. One or more of the following indicates this deteriorating:

( 7-50

EM029421-0 (en-us)

Drastic loss in rope diameter and lay lengthening.

Outer wire abrasion.

Broken wires.

Corroded wires.

Marks indicating mechanical abuse, distortion or crushing.

Inspect rope sheaves often. Check sheaves and drums for proper alignment.

Do not allow wear at rope sheave groove. An old rope wears a groove to a reduced radius. This groove crushes or deforms a newly installed rope.

Avoid sheave groove or drum lagging from assuming rope lay shape. Alternate right and left hand lays, if needed. Keep sheaves and drum free of rough spots, nicks and burrs. Never use cracked or chipped sheave.

Maximum rope life and the best service evolves from extreme care in handling and installation. This is important. Working a new rope at reduced loads gives the rope lay time to acquire a permanent set. Slow acceleration and deceleration of load and eliminating sudden actions are good habits to develop. Avoid overstressing a rope by jerking or catching a heavy, falling load.

Lubrication remains the most important item in rope care. All rope is lubed when manufactured. Generally thin and filmy, this lube eases the manufacture rather than preserve the rope. This film drys rapidly or dissipates thru surrounding conditions.

Lubricate every rope at installation and keep coated thru continued service.

Lubricant serves to reduce internal friction wear and the outer wire wear against sheave or drum. Lube protects rope from weather and corrosive air, too.

Marion recommends a light, penetrating type lubricant (WRL) containing antirust and corrosion agents and anti-wear additives. This lube saturates rope interior thus reducing internal friction providing a protective outer coating.

The rope lubricant selected may be an asphaltic type containing volatile solvent or diluent which allows strand and core penetration. This lube type works well for operations in highly abrasive material or water submersion.

One method of rope lubrication utilizes an automatic system that provides a drip fixture above sheaves on boom point, gantry, and fairlead.

7-51

I

EM029421-0 (en-us)

Another method requires hand pouring of iube onto rope after brush or air jet cleaning. In either method, the rope must remain coated at all times.

(

Inaccessible boom supports and bridge strands need lubricant applied at and around boom hoist sheaves, as well as, the dead end anchor area. Spray can lube helps here.

Figure 18 Proper Methods of Seizing

PROPERLY SEIZING wire rope ends prevent the strands from slipping. Any strand movement causes uneven load distribution in the strands and reduces rope life. (See Figure 12)

Sketch of Method No. 1 for applying seizings. At A the turns of the seizing wire are spread apart to illustrate Seize rope BEFORE cutting. method of applying them. Completed seizing is shown at B. Tighten wrap, (a soft, annealed wire), about strand size wire; around rope. Pull wrap tight. Twist wire end secure. Use 1/4 inch A wrap length on all rope up to 1/4 B Sketch of Method No. 2 for applying seizings.

At A the inch. On all other rope, measure turns are spread apart to show method of applying them. wrap length at least one rope Completed seizing is shown at B. diameter in length. Place the first wrap about 1 to 1-1/2 inches from the intended cut. Then place a second wrap or seizing about 4 to 6 inches from the first.

Use a portable cable cutter whenever possible. Often a flame cutting torch is used and generally fuses the strand and wire together. Do not use a melting tip here.

Figure 19 Applying Wire Rope Clips

The Right Way to Clip Wire Rope

Space wire rope clips about 6 rope diameters apart. Tighten clip on rope BEFORE placing rope in tension. Then retighten after rope is in use. Any rope diameter loss caused by pulling on rope, loosens clips. Retighten clips.

The Wrong Way to Clip Wire Rope

Only one correct method of attaching U-bolt clips on wire rope exists. The clip base must bear on the live end of rope. The U of the bolt bears on the rope dead end (see sketch). Otherwise, the U-bolt kinks or cuts the anchor live end and causes failure.

( 7-52

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Wire rope adjacent to the dragline bucket is subject to the greatest abrasive wear. This is true of the shovel dipper ropes too. When this rope section shows excessive wear, remove the rope socket, seize the worn area and cut off.

Examine this worn rope to reveal any irregular or internal rope fractures. This exam determines subsequent cuts.

The correct spacing and number of clips is shown in the table 6 below.

TABLE 6 WIRE ROPE CLIP SPACING Rope Diameter (in inches) 5/8 3/4 1 1-1/4 1-1/2 2 2-1/2 3

Rope Diameter (in mm) 15.

19.

25.

31.

38.

50.

63.

76.

Clips 3 4 4 5 6 8 8 9

Space (in inches) 4 4-1/2 6 7-1/2 9 12 15 18

Space (in mm) 101 114 152 190 228 304 381 457

Inspect these ropes often. Replace any that show signs of deterioration. Due to the elasticity factor involved, use only those ropes recommended by Marion Parts Department. Never use larger or smaller diameter rope. When proper rope is unavailable, contact Marion Engineering Department.

Information for these instructions and cautions obtained from MPSD C1-897.

BOOM STRAND PENDANTS Bridge or structural strand may be seen as layers of wires around a center wire.

This forms a symmetrical section. Additional layers increase the strand diameter.

The packaging and handling of the strands, especially during installation, requires great care in preventing damage or possible disturbance of these outer wires.

Strand pendants normally are shipped in one of three manners; coils, reels or laid out straight on flat cars. A number of common precautions, to all three, need to be followed; even though each packaging unit requires special handling.

Coiled or reeled strands have the socket at one end tagged, STARTING END. This means to start uncoiling or unreeling with THIS socket.

On all strands with end fittings attached, each fitting is tagged to identify FRONT END or REAR END.

7-53

Bridge or Structural Strand

EM029421-0 (en-us)

A

CAUTION!

ATTACH lifting slings to socket ends when unpacking strand pendants in field.

Use either a nylon or wire rope sling if necessary to lift on body of strand assembly. When using a wire rope sling, cover the strand with protection such as belting, rubber tire, etc. This act prevents damage to the zinc coating or the nicking of strand outer wires.

When lifting the strand body is the only way, use great care to allow the radius of the strand curvature at lift point to be large and thereby minimize any wire displacement.

Do not pull strand over sharp edges. Any short bend during handling might result in permanent damage to arrangement and surface of the wires in the strand. Particular care must be used to insure that nothing done in handling causes nicks in strand outer wires. Wood planks or timbers are recommended for use to prevent strands from contacting the ground when these strands are laid out before installation or for storage.

Correct high or displaced wires noticed during handling, particularly in large diameter strands, BEFORE installing strand assembly. This condition indicates that during unreeling and handling, one or more outer wires suffered from squeezing or were forced out of normal position by the other wires in the strand. It does not mean defective manufacture. These displaced wires may be restored to proper position while the strand is stretched out by using a hardwood block and a hammer or rubber mallet. Please do not use anything that might nick the wires or damage the coating or outer strand wires.

Tap the wires back into position. Often this means moving other outer wires to replace the high wire into original position.

Intermittent bands applied to large diameter strands during manufacture minimize outer wire displacement while handling. These bands should remain on the strand until after installation.

After accurate measurement at the factory, a longitudinal stripe is placed on the strand. During installation, it is extremely important that this longitudinal stripe is kept in a straight line and NOT permitted to spiral around the strand.

If rotating the strand to align socket pin hole is absolutely necessary; then its BEST to rotate in a direction opposite to the strand lay. For example, right lay strand (outer wires spiral to the right) may be turned in a counter-clockwise direction. Left lay (outer wires spiral to left) may be turned in a clockwise direction. It is IMPORTANT that the strand be turned so as to tighten, rather than loosen the lay of the outer wires. Exception: only if adjustment is very small.

7-54

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EM029421-0 (en-us)

Following installation, and periodically thereafter, lube the strands at socket base for a minimum distance of three feet. (one meter)

A

CAUTION: DO NOT attempt to uncoil the strand in the manner often used to uncoil a garden hose. (DO NOT lay coi! on ground and carry one end away from it). This is wrong.

This method easily results in destroying the strand.

When using a swift turntable for larger diameter strands shipped in coils, as recommended, use also a drag-type brake to prevent any rapid rotating speed from exceeding the pulling speed. This prevents kinking and looping. The pulling device attaches to the socket tagged, FRONT END. Observe all the common precautions also. Remember the longitudinal stripe and keep it aligned.

I

7-55

EM029421-0 (en-us)

REPAIR WELDING PROCEDURES

When weld repair is required, it is extremely important it be done correct because weld repairs can cause damage to an entire structure if performed incorrectly. Since several difficult to control variables can ruin a weld repair such as impurities in raw materials, defective welding equipment and state of normal wear it is recommended that you request a factory weld procedure.

(

The Weld Engineering Department at Marion issues repair procedures when a request is received from a customer. It is always better to see the repair problem, however, this is not always possible. Therefore, information received must be accurate. For example, its important to know the exact size of the defect, its exact location, available welding equipment, and whether the repair will be done on the machine or in a building. Machine information, serial number, part name and identification should also be sent to the service department. Pictures and sketches are also helpful to develop a good repair procedure.

Each step of a welding procedure must be followed. Years of experience in the manufacture of mining equipment have proven major failures have occurred due to inadequate field repair of certain structures.

Weld repair jobs should not be rushed. The worn or fractured area must be evaluated carefully to determine how the repair should be accomplished. It is good practice to listen to experienced welders and ask for their input if available.

Here is a ten-step outline to follow when developing any weld repair procedure.

1. Clean the worn or fractured part or area to be repaired.

2. Analyze and inspect the fractured or worn component for proper reporting.

3. Determine the type of material you will be repairing or rebuilding.

4. Prepare the part to be repaired or rebuilt.

5. Determine the electrode and process to be used.

6. Preheat before welding if required.

7. Weld by using good welding techniques.

8. Post heat if required.

9. Slow cool.

(

10. Inspect the repair.

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STEP 1-Ciean the Worn or Fractured Part or Area to be Repaired or Rebuilt One of the most important considerations of a welding repair procedure is to clean the fractured area or worn part of all oil, grease, paint, moisture, dirt, rust, spalled material, or any other material that may be detrimental to a weld.

Hydrogen has a bad effect on the properties of weld metal and can be found in most of the mentioned contaminates. As molten weld metal cools and solidifies, the hydrogen is rejected from the solution and becomes entrapped in the solidifying weld metal. It will collect at grain boundaries or at discontinuities of any type where it will create high pressures, which will in turn cause high stresses within the weld. Theoretically, these pressures and stresses could lead to minute cracks in the weld metal which could develop into larger cracks.

Hydrogen will gradually escape from the solid steel over time.

Any spalled material should be air carbon arc gouged off or ground off because contaminates can be trapped under the spalled material. The spalled material may not allow the welding arc to penetrate to solid material.

Inspect the worn or fractured areas closely by visual inspection and/or nondestructive testing such as magnetic particle inspection or dye penetrant inspection. This will help determine the extent of the fracture. If one of the NOT techniques are used, make sure instructions on proper use are followed.

Some methods of cleaning a part are steam cleaning, blasting, or burning off the oils and greases with a torch. The cleaning process must be analyzed depending on how and where the part will be repaired and the type of material that requires cleaning. If a heating torch should be used, make sure the operator of the torch is supervised closely. The flame should not be concentrated in one spot for long periods of time, but should be swept back and forth across the part. The burned ash can then be brushed off with a wire brush. Clean a large enough area around the fracture or worn part so that no contaminates reach the repair area.

STEP 2-Analyze and Inspect the Fractured or Worn Component for Proper Reporting The initial task is to seek out and compile as complete a history as possible of the failed or worn part. The following is a list of items that will be useful in analyzing the failure.

1. Determine when, where and how the failure occurred. Interview the operators.

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2. What is the service history? Length of service? Was an accident involved?

Have there been other similar failures?

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3. Examine the part visually. Prepare sketches and take photographs to provide a complete record.

4. Where is the failure located? (base metal? heat affected zone? weld metal?)

The every-day mechanic that is not familiar with metallurgy can look for certain defects in a fracture such as incomplete fusion of a weld, porosity, inclusions in the weld such as slag and oxides and inadequate penetration. If a part has completely fractured, you can see small chevron-like arrows pointing to the stress concentrator.

There are two non-destructive testing methods the average mechanic can learn to use to get a better idea of severity of the failure in a part or to help examine a visual indication.

Method one is dye penetrant testing where a red dye is sprayed over an indication. This red dye will penetrate into any crack. After the dye is left to penetrate for a time, it is wiped clean. A white developer is then sprayed over the indication area. If an indication is evident, the red dye will show through the developer. This is perhaps the easiest and quickest way of determining the extent of the problem.

Method two is magnetic particle inspection testing. An A/C yoke and iron powder is all that is required plus some training. The yoke, when placed across a suspected defect, will create a magnetic field. If there is a defect in the area, the magnetic field will be interrupted. The iron powder, when sprinkled over the area, will align with the defect.

STEP 3-Determine the Material that will be Repaired Most of the materials used to build mining equipment can be weld repaired.

However, there are materials that are more difficult to weld successfully if their full service characteristics are to be retained. It is important to know the type of material so the repair procedure specifies the correct preheat and electrode.

Some methods of determining the material are: 1. Check the parts book.

2. Check with the manufacturer's service department.

3. Drill out shavings or cut off a small piece of material and take it to a lab for analysis.

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Step three is perhaps the best possible method of determining the material. If the above methods are not feasible and it is determined the risks are minimal, an analysis of the equipment can be made by categorizing the parts. The categories would be structural components such as plates, beams and bars, castings, and forgings. The structural components (plates, beams, and bars) can be divided into four areas; such as, (1) mild steel, (2) medium strength steel, (3) high strength steel, and (4) wear resistant type steels. Steel castings and forgings can be categorized the same way; (1) low carbon, (2) medium strength and wear, and (3) high strength and wearability.

The electrode tensile strength and the preheat parallel the material categories as follows: Type of Steel Mild Steel

Electrode E?OXX

Medium Strength Steel

E70XX,E80XX

High Strength and Wearability Steels

E90XX, E 1OOXX, E110XX

Preheat

150°F (66°C) to 300°F (149°C)

Castings & Forgings -Low Carbon

E?OXX

-Medium Carbon

E70XX,E80XX

-High Strength and Wearability

E90XX, E 1OOXX, E110XX

250° F ( 121 °C) to 600° F (316°C)

Lower and upper frames of draglines and mining shovels are usually made of structural mild steel. The boom and its components are made of medium strength steel. Buckets and dippers use high strength wear resistant type steels. There are very few castings made of low carbon steel. The majority of steel castings can be classified as to the job they perform. Hubs and bearing supports can be considered as medium strength and wear while gears, sheaves, shafts, bucket castings are high strength, high wear components.

Brake shoe components are usually made of cast iron, therefore, it is not recommended to weld on these parts because of the product liability risk and the poor reliability of the weld.

Do not weld or tack any lifting lugs, aligning lugs, or hold down lugs on any parts unless you know the type of material. The lugs could pull out at the weld because the right procedure was not used. This could cause damage to a part, a person, or some other parts. Do not over-weld when adding attachments such

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as lugs to a part as this may cause more damage. A good rule of thumb is that the combined fillet welds should be of the same size as the thickness of the lug or attachment.

STEP 4-Preparation of the Defect or Worn Part

Proper preparation is half the job, therefore, it is important to evaluate each part on its own merit. Some points to consider are as follows: 1. How large is the crack or defect?

2. Is the crack completely through the thickness?

3. Will distortion be a factor?

4. Can two welders weld opposite each other in order to control distortion or must all the repair be done from one side?

5. Will the welder be able to withstand the preheat if required?

6. Can the welder get into a position to do a good job?

7. Does the cost of repairing the part compare favorably to buying a new part?

These points are important factors when evaluating how the defect should be prepared for welding. A welder can repair most defects, add modificiations or repair worn parts as long as good equipment is available to him such as the correct clothing, head gear, exhaust systems or respirators and platforms for the job. If the welder is kept comfortable and given the required equipment and consideration, a quality job can be expected.

Methods of metal removal to be considered are: 1. Air carbon arc gouging.

2. Grinding.

3. Machining.

4. Oxyfuel burning.

Before any weld repair is started, a survey should be made of the area and all safety considerations satisfied such as fuel tanks, oil lines, electrical cables and toxic materials.

A decision should be made whether the part will be repaired on the machine or disassembled and repaired in a shop or on the mine floor.

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All machined surfaces or machinery in the vicinity of the repair should be protected from spatter from welding and air carbon arc gouging sparks. Silicon blankets or steel plates can be used to protect machinery or machined parts.

Attach the welding ground directly to the part that is being repaired. Do not allow welding current to go through bearings. Welding current could arc the bearings and shorten the bearing life.

If the crack opens up during the operation of the machine, the part should be realigned. This can be done many times right on the machine. The part should be brought into as close an alignment as possible and braced, clamped or tack welded to maintain the alignment.

When removing cracks or defects, a "V" groove should be made with a 30°-45° included angle and tapered at the ends. This allows for proper fusion, good slag removal, and access to the groove. The groove should be free of any gouges or notches and cleaned of any slag or carbon.

If a defect or crack is 8 inches (200mm) or less in length, begin removing the defective material by starting at least 1/2 inch (12.5mm) beyond each end of the crack and remove metal by working toward the center.

If the defect or crack is 8 inches (200mm) to 12 inches (300mm) in length, begin removing the material by starting 1/2 inch (12.5mm) beyond the crack and removing material to about half the distance of the crack. Repair weld this much of the defect and cascade the middle end of the weld. Finish removing the second half of the defect and complete the weld repair.

When the defect or crack is over 12 inches (300mm) in length, the crack should be divided into three sections. The weld metal can be used to help pull the part in to a closer fit-up because of weld shrinkage. This should be considered when deciding whether to start removing metal and repair welding at the two ends 1/3 of the crack or starting at the center 1/3 of the repair. Repairing a section at a time will help keep alignment and distortion to a minimum along with any required support braces. Again cascade the ends of welds so the next weld segment will blend in with the former weld. The back step method is another way to help control distortion. A worn out part should be checked for any spalled metal. This may be removed by grinding or machining.

Before starting to weld repair the part, check the "V" groove or worn part with magnetic particle or dye penetrant inspection to ensure all cracks have been removed.

Preheating of the part before preparing it for a weld repair is essential to reduce the thermal stress. It is good practice to preheat prior to cutting or gouging to at least one-half the temperature that will be used for the repair welding operation.

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STEP 5-Eiectrode Selection

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When selecting the right electrode, there are certain factors to consider. These are: 1. Welding process.

2. Welding position.

3. Welding current.

4. Service conditions or specifications.

1. Welding process: is the repair going to be made on the machine, somewhere in the field, or in a shop? What type of welding process is available?

Shielded metal arc (stick), gas metal arc, flux cored welding (gas or gasless), submerged arc, or gas tungsten arc welding process? What is the extent of the repair?

The most common welding process is the shield metal arc welding process or stick. With the availability of new portable power sources and arc welding equipment, any of the processes mentioned could be used. For the rebuilding of rollers and shafts, the submerged arc process is very practical. The results are a smooth, neat overlay or build-up of high quality weld metal. In the past few years, a number of electrode manufacturers have developed small diameter flux cored electrodes for all position welding. If the repair is extensive, the flux cored process will reduce the repair time.

A process that is often overlooked for small repair jobs is the gas tungsten arc welding process, commonly known as T.I.G. With this process, almost any type of material can be welded. The T.I.G. process is not a high production process but the weld metal is of high quality. Any repair can be blended in with the surface of the part with very little grinding. The heat affected zone in high strength cast steel or forgings is not too much harder than the parent material. It can be used for the repair of gear teeth, small repair areas in almost any weldment, tubing and for the repair of hand tools.

2. The second factor to consider is the position the part will be repaired. If the repair can be welded in the flat position, larger electrodes can be purchased, and therefore, decrease the time to complete the repair. Depending on the type of repair and how critical the repair may be, the smaller electrode should be used. If the repair must be made in the vertical position, the electrode must be an all position type electrode.

3. A third factor to consider when purchasing electrode is the type of welding current. If the welding machine is a (stick) AC transformer, an electrode

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should be purchased for this type of machine. The power source may be a DC rectifier constant current or a DC constant voltage type of machine, with either positive or negative polarity. Electrode manufacturers have developed electrodes for each different type of welding current. You must also consider the size of the welding power source or the output amperage and voltage of the machine. This will determine the size of the electrode that can be used.

4. Since the type of material has been determined in Step 3, a decision is required on the chemistry and mechanical properties of the electrode to use for the repair or rebuilding of a part. The cause for the fracture can have a bearing on the type of electrode to use. A good rule of thumb is to use the same tensil strength electrode as the parent material when welding full strength joints. However, most generally, all fractures are in parts that are highly-stressed and rigid because of the configuration of the part and its function. Therefore, the weld metal must be ductile to compensate for weld metal shrinkage. A lower strength weld metal with good ductility would then be used.

STEP 6-Preheating Before Welding

Preheating involves raising the temperature of the base metal above the temperature of the surroundings before welding or cutting. The entire part may be preheated or, if local preheat is required, only the vicinity of the joint to be welded is preheated. The preheat temperature depends on the composition of the steel, the rigidity of the base metal members to be repaired, the ambient temperature and repair procedure.

In Step 3 it was determined the type of material requiring the repair. This information is also helpful in determining the preheat temperature. The required preheat can be determined by the manufacturer's recommendations, published preheat charts or using a carbon equivalent equation. The benefits received from good preheating practices are: 1. Reduce the danger of weld cracking.

2. Reduce heat affected zone hardness.

3. Minimize shrinkage stresses.

4. Lessen distortion.

5. Help gases, particularly hydrogen to escape from the metal.

It is important to maintain the preheat temperature throughout the repair. The welding temperature should never be allowed to become lower than the preheat 7-63

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temperature, except when using a buttering technique which will be discussed later. The preheat can be checked by different means such as thermometer, temperature indicating crayons or materials and other devices.

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Once a repair has been started by preheating and welding, the part should be worked on until completed.

When repairing a part in the field or shop, all the convenient facilities are not available for preheating. Probably the most common preheating device is a heating torch which uses oxygen and some type of fuel or another preheating device such as resistant heaters. It is important when using a preheating torch to allow the heat to soak into the part gradually, a minimum of 3 inches (76mm) beyond the repair area in all directions. The surrounding repair area should be covered with an insulating blanket to keep the heat from dissipating too fast. A temporary furnace can be made to preheat large parts. All repairs should be sheltered from cold drafts. This can be done by building a temporary shelter around the part if it can not be taken to a shop.

'

Do not short change the repair by skimping on the preheat. It is always better to preheat than to repair a job without preheat plus the chances of a successful repair are better. The only steel where preheating temperatures can be detrimental to the repair is austenite manganese steel. This type of steel may be used on bucket or dipper lips, track pads, drive tumblers and dipper racks. The preheat and interpass temperature should never go beyond 400°F (204°C).

This steel can be quickly determined by the use of a magnet since it is a nonmagnetic material.

STEP 7-Welding Techniques The first and most important part of a repair procedure is to pick your best welder or welders who will follow explicit welding repair procedures. This type of welder is a person who enjoys such challenges even when he is in an uncomfortable position and the preheat is uncomfortable.

A technique highly recommended for a repair is to butter the groove with weld metal. What is buttering and what does buttering do for you? Buttering is the addition of one or more layers of weld metal to the face of the joint or surfaces to be welded. Every weld repair of a large structure can be considered a high restraint joint, therefore, buttering is highly recommended. If we examine the mechanical properties of parent material and weld metal, we find the weld metal will have the best ductility. We know when weld metal cools shrinkage stresses will be created, therefore, when the center joining passes are put in, the weld metal will be pulling on the butter passes instead of the parent material which has less ductility.

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The buttering assures all finish weld beads will be made only into previously deposited weld metal resulting in maximum tempering of previously created fusion and heat affected zones in the base materials. Buttering can also be used to reduce the high preheat required for high alloy steels. Many times a repair does not require the hardenability or heat treatment of the parent material, therefore, high strength electrodes are used for the repair. The parent material can be buttered with two layers of weld metal at the recommended preheat for the parent material and then the preheat can be lowered to about 200°F (93°C) for the comfort of the welder. A good example would be the changing of racks on dipper handles. The racks are usually made of an alloy · steel which requires a preheat of 450°F (232°C)-500°F (260°C). The rack bevel could be preheated and buttered with a layer of the required weld metal.

The racks would then be installed on the dipper handle and then preheated to about 200°F (93°C)-250°F (121 °C) and welded eliminating the high preheat required to weld the assembly.

Do not forget to use electrodes out of a freshly opened can or from an electrode holding oven. Make sure any flux cored electrodes are stored in a dry place. Any entrapped hydrogen can result in a failure. Another good technique is to use stringer beads. In other words, do not weave. Wide beads result in high shrinkage stresses. When using stringer beads, the grain structure is more refined and each pass will somewhat temper the previous bead.

Peening with a blunt-nosed tool can be used to reduce locked up stresses, to maintain original dimension and alignment and to help prevent weld metal cracking in rigid sections. The pneumatic hammer should be sufficiently heavy in strike force to be effective without producing excessive work hardening.

CAUTION! The first and last layers should not be peened.

The use of templates can be very helpful in gauging the build up of weld metal when rebuilding sheaves and rollers. The rebuilding of parts should be done on a lathe or some type of positioner where the part can be rotated so an even preheat will be distributed around the whole part.

After the welding has been completed, check the repair for any undercuts, overlaps, or any other notch type discontinuity while the preheat is still up to temperature. Make any repairs necessary at this time.

Hammer peening the weld toe rounds the toe profile, thus smoothly blending the weld metal into the parent plate. Properly controlled peening has been shown to result in a substantial increase in the endurance of welded joints in highly restrained joints.

After the repair cools, grinding of the weld toe is another method for a smooth transition between the weld metal and the parent plate.

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STEP 8-Postheating The best practice is to thermally stress relieve a part that is highly stressed or requires machining. This is not always possible since parts of mining equipment are large and too complicated to stress relieve. Many times electric resistant heaters can be used for preheating and postheating of the weld area.

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Weld repairs in alloy steels where it is not possible to stress relieve, but must be used as welded because of the size and configuration of the part, the preheat and interpass temperature should be held for one hour after welding.

The objective is to permit the weld to transform from Austenite to a softer microconstituents rather than to martensite and thereby to minimize the possibility of cracking without undue sacrifice in mechanical properties. Postheating will also help in releasing entrapped hydrogen. Every precaution is important when making weld repairs.

STEP 9-Siow Cooling It is very important to keep any cool drafts away from parts which have been preheated, welded, and postheated. All parts should be covered by insulating blankets, returned to a furnace, covered with insulation or covered with sand for slow cooling. Cooling rates should be controlled so the temperatures decreases about 50°F ( 10°C) per hour until reaching 150°F (66°C).

Many times welders will set a repair job on beams and will cover the top of part but forget about the area between the floor and the part. Unfortunately, the greatest draft occurs along the floor. This could cool the part unevenly and cracking could occur. Therefore, it is important to slow cool the whole part evenly.

STEP 10-lnspection of Repair

The last important step is to inspect the completed weld after it has cooled to the ambient temperature. Make sure there are no notches which could become a stress riser. Grind welds so they blend in with the parent material.

Non-destructively inspect the repaired welds with dye penetrant or magnetic particle inspection discussed earlier. If it is important to examine the whole weld, then a technician with ultrasonics or x-ray expertise should be contacted.

If any questionable weld should appear, it should be examined and repaired before the part is put back into service or it will not be long until the part will again have to be removed and repaired.

Make a final measurement of all important dimensions. This will show your success of staying within the dimension or tolerances. If the repair is successful, record the procedure for future reference.

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EXAMPLES OF CORRECT WELD REPAIRS: A sheave with a rope groove worn. Rebuild and keep as a spare.

STEP 1:

Clean the sheave of all grease and oils for inspection of any fractures and clean it of contaminates that would be detrimental to welding.

STEP 2: Inspect the sheave visually and with magnetic particle inspection for signs of any other fractures. Compare the cost of rebuilding the groove with a new sheave. The decision is made to send the sheave to the manufacturer for rebuilding.

STEP 3:

A review of the print shows the material is MN-MO cast material.

STEP 4:

The sheave will be prepared for welding by sending it to the machine shop for a light clean-up cut to machine off any spalled material.

The sheave will then be mounted on a welding positioner for rebuilding. Make a template to use as a guide to measure the depth of the weld metal.

5:

Since the manufacturer has flame hardening equipment, a heat treatable type electrode will be used such as 4130 flux cored electrode and a constant voltage power source.

STEP

STEP 6: Use two preheating torches while rotating the welding positioner to preheat to 350°F (177°C). Use a temperature indicating device to continually check the preheat throughout the welding operation.

STEP 7:

With automatic welding equipment, start welding at the center of the groove and as the groove builds up, start each layer at the groove walls and work to the center. Clean each pass of slag. Use the template to determine the correct amount of weld metal build up for machining. Once preheating has begun, do not stop until the job has been completed.

STEP 8:

Since this part cannot be stress relieved in a furnace because of the machined hub, continue postheating the groove area for one hour.

Keep the heat at 350°F (177°C)-450°F (232°C).

STEP 9: Slow cool by turning the torches down while the sheave is still rotating so it cools at a rate of 50°F ( 10°C) per hour until it reaches 150°F (66°C).

STEP 10: After the sheave has cooled down to ambient temperature, inspect the weld visually and by magnetic particle inspection.

STEP 11: Send the sheave to the machine shop for remachining to print contour.

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STEP 12:

Flame harden the groove.

A second example of weld repair is a broken tooth in a rotating gear of a shovel which needs repair and have available as a spare part.

STEP 1:

Remove the gear and clean of grease, oil and any other contaminates.

STEP 2:

Inspect the gear for any other fractures. The reason for the tooth breakage was a rock fell in between the gears as they meshed. The tooth broke out at the root. Since the tooth is the only serious problem, the decision is to repair it.

STEP 3:

The material is AN AISI 8630 cast steel material per the manufacturer's service manual.

STEP 4:

Since a local preheat of 500°F (260°C) to 550°F (288°C) is required for this material and weld metal shrinkage is involved, some type of fixture is required to control distortion. Burn, machine and drill a 1 1/2 inches (37.5mm) thick half moon plate that will fit the inside I.D. of the gear. Make a steel template that will cover the contour of three teeth to use to align the broken tooth. Double bevel the tooth at a 45°-50° angle leaving an approximate 1/8 inch (3 mm) root face. Grind any burning serrations on the tooth and any notches in the gear rim. Align the tooth with the steel templates. Tack a stiffener across three teeth on each side of the gear, one of them being the broken tooth, to hold it in alignment during welding.

STEP 5:

In Step 3 the material was determined to be AISI 8630 which, in its normalized condition, is about a 100,000 PSI. Therefore, it is recommended that a 100,000 PSI tensii strength electrode should be used because of the function of the tooth. Because of the length of weld and the shape of the gear, the shielded metal arc process would be recommended using an AWS E10018 type electrode. Use small diameter electrodes such as 1/8 inch (3 mm) and 5/32 inch (4 mm) diameter.

STEP 6:

Slowlypreheatthe gear and tooth to 550°F (288°C) at the repair area. Pack insulation or heat blankets around the repair area to help hold in the heat. Do not concentrate the heat on the broken tooth or allow the heat to go above the heat treating properties or you will lose the hardness of the tooth. Make sure the repair can be completed once preheating has been started.

STEP 7:

Weld two passes in one side of the groove and back gouge to sound metal. Weld second side to the same width as the first side and then

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use a balance welding technique by alternating a pass on each side of the tooth. Do not weave but use a stringer bead technique. Clean each pass of slag. If a GTAW welding machine is available, blend in the last two layers with this process. Peen each bead except for the first bead and last layer. Visual inspect the completed repair job. Use the template during the welding operation to check on any distortion.

STEP 8:

Postheat by holding the heat at 550°F (288°C) for one hour after welding has been completed.

STEP 9:

Allow the gear to slow cool at a rate of 50°F ( 10°C) per hour until it reaches 150°F (66°C). After it reaches ambient temperature, grind the root contour.

STEP 10:

Inspect the repair visually and with magnetic particle inspection.

Check all critical dimensions. Check the hardness of the tooth.

A weld repair can be very successful if it is thought out carefully and these repair weld procedures are followed.

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0-RING GUIDE The dilemma of how to identify an 0-ring generally derives from the question; "Is it a gasket, seal or packing?" Hence the confusion. One solution is to rely on the part . I Secun"ty num b er, num b er. M uc h lI"ke a SOCia it identifies even though the name may be confusing. If the part number (Social Security number) is correct, the name doesn't complicate the issue. Chasing down a part number takes a bit longer, but in the end; it is well worth it.

Note How the Seals Fills Irregularities

An 0-ring's function is to confine and prevent passage of liquids and gasses under pressure from the part or joint. Perhaps simply stated; an 0-ring closes off a passage to prevent loss or escape of fluid or gas.

One basic principle of 0-rings is compression under load to fill the machined surfaces in mating metal to block off fluid flow. Truly effective 0-rings fill surface irregularities and maintain this ability. This is done in the following manners: SQUEEZE is the ability of distortion while still blocking a passage. This does not mean CRUSH. Effective and usable squeeze is considered as from 12 to 35 percent. I nsufficient squeeze causes leaks, almost always at low temperatures. Too much squeeze outright destroys the 0-ring or causes it to cold flow to a premature set.

RECOVERY (or resilience) describes an 0ring acting as a surging spring over long periods. Failure to recover after deformation is called compression set.

METAL to METAL contact is vital in creating correct squeeze while preventing destruction. A well designed seal transmits torquing loads thru the metal NOT the 0-ring.

f

;

Too Much Squeeze

Too Little Squeeze

Recovery (or resilience)

Compression Set

Metal to Metal Contact

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Static seal use is generally simple.

Three common types are shown at right.

When pressure exceeds 1500 psi, the backup ring is used. In static face seals, backup rings may not be needed.

_ . , l

H1 Dla. When Direction of Pressure Is Inward. H 1 Min.= D-ring Mean I.D. Plus 1% up to 0.060 Max. H 1 Min.= 0-rlng Mean I.D.

.

.

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:

~

F (Equal to L since E = Zero for End Face Seals)

""• G ""'

••m "• G "" 0

1W l_lh. ~~::. ,,',"'"~A ..._,= ]TI'I2E C Dla. A Dla.

MOST 0-RING PROBLEMS return to three factors:

D Dla. A-1 Dla. (A-1 Max = B Min + 2 L .1\/laX)

Ho Dla. when Direction of Pressure Is Outward.

Ho Max.= 0-rlng Mean O.D. Ho Min. = 0-rlng Mean 0.0. Minus 1% up to 0.060 Max.

1. Size: Using incorrect size causes ineffective or totally destroyed function.

2. Compatibility: 0-ring material must be compatible with the chemical, thermal and mechanical surroundings.

3. Installation: Improper handling during assembly causes a great deal of grief.

Size cannot be picked out by color code. Exact replacements are found ONLY by part number. DO NOT ATTEMPT matching size by feeling and comparing the new with the old. One other detail here: Do not open package until 0-ring is needed for installation. This prevents mixing, rolling on floor, dropping in sewer; among other disasters.

POOR INSTALLATION may begin with the removal of the old seal.

1

Some points on removal:

2

Removal involves parts with close tolerance surface finishes.

3

In critical surface areas; scratches, abrasions, dents, and other surface mars cause faulty seals. This results in component failure.

4

5

Typical 0-ring installation tools

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DO NOT USE pointed, sharp-edged or hardened steel tools (screwdrivers, church keys or knives) for removal or installation of backup rings or seals. Softmetal tools of brass or aluminum, plastic, wood or phenolic rod when formed into desired shape save the critical surfaces.

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Tool surfaces need to be well rounded, polished and no burrs on working end.

This obviously prevents scratches. (Typical 0-ring tools shown on page 71) Removal from cylinders and pistons means every effort is needed to avoid contact with machined surfaces.

'-Back-up Rings

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0-rlng

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o-/

\-i.'~)' ~

~ ;(~/\ ~ ,.::~ Cylinder-~__. ,·f~~ · , 0-ring Removal Tool" (Hook)

Extractor Tool

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----

____-, ~ "'-,II

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Cylinder Mouth

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-----

Back-up Rings

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O·ring Removal Tool (Hook)

Extractor Tool

(P~II

Type)

-

N

~....

t(

0-ring Extractor

''

Tool (Push Type)

-~~ - ' ' ':>...

,.,~· •J

----

Cylinder

0-ring

UO·ring

0-ring '

:/ / -

. I.

,-~-~_

;:--~

',~ y,~,)J_

~-,/ ' "

'--'u~" \..:: : : /

0-rin~,'--~~~;~,J ' /,'//

Typical Removal Utilizing ' , Push Type Extracting Tool & Hook Removal T~

~· 1

r

-:;~"....

~ ~'

: '"&t ·1 1 '( ~ ,...._

Cylinder Mouth

1( /,· ....._ "-"--.. 0-ring Removal ;r--==== ~==::::> ',-\:.:_~ Tool (Hook) 0-ring Extractor 0-ring Removal Tool (Push Type) Tool (Hook)

Back-up Rings

0-ring Extractor Tool (Wedge)

1 0-ring

I

0-ring Removal

~~~~~--Tool (Hook)

Typical Single 0-ring Internal Extraction Utilizing Wedge Type Extracting Tool & Hook Removal Tool

Typical Duat 0-ring Internal Extraction & Simultaneous Removal

~====·==== D-ring Removal Tool (Hook)

O·rlng Extractor Tool (Wedge)

~4~ i!rL f

'~Removal ....

--'\

0-rlng

Spoon

0-ring Extracting Tool (Wedge)

Typical External 0-ring Removal Utilizing 0-ring Removal Spoon

Typical Single 0-ring Removal Utilizing Wedge Type Extracting Tool and Hook Type Removal Tool

CAUTIONo Do Not Permit Unnecessary Contact of Tools With Bearinq and Cylinder Wall Surfaces. Avoid Dropping Tools Into Cylinders

NOTE. P.fter 0-ring is Dislodged from Groove, Hold Spoon Tool Stationary Simultaneously Rotate and Withdraw Piston from Ring

( \

7-72

EM029421-0 (en-us)

0-rings in service undergo slight swelling and softening which may be nonvisible, when worn. Increased damage can occur on re-installation, so use ONLY NEW RINGS. Inspection of old, damaged rings can identify failure from extrusion, wear, torsion set, excessive permanent set or rolling in the groove.

Excessive extrusion may indicate the use of the wrong ring or backup rings were not installed. Irregular wear may indicate a rough spot or eccentricity in the cylinder. The ring may also fail from defect that careful preinstallation inspection may have seen. Some 0-rings, lacking proper resilience, might have been subjected to overtemperatures. Since rings are not designed for high temperatures, they should be replaced, regardless of appearance, once known rings have been subjected to unusual heat. Overheated rings are hardened, crack with flexing, take a set and lack resilience. Once old ring has been inspected, cut it in two pieces and THROW AWAY.

Frosty Appearance Excessive Temperature

Permanent Set

a

Abrasion

Excessive Rolling In The Groove

Before installing, check surfaces and rings. Metal surfaces must be free of dust, dirt and gunk. Stoddard solvent (kerosene base with rust inhibitor) cleans parts and leaves a good surface for lube to adhere to. However, these cleaning fluids can cause some rings to swell. So check that cleaning fluid does not harm the 0-ring if left on surface.

Once the proper 0-ring is selected and part number is rechecked; examine the ring closely for defects, dirt or lint.

Throw out faulty rings after cutting so they do not get mixed with good ones.

Discard new rings that are too tight once installed, do not return these to storage.

Once installed; an 0-ring seats snugly, but freely in its groove.

PREPARATION requires checking the surface for scratches from fingernails, tools or fitting threads. DO NOT pinch ring between boss and fitting. Watch for sharp edges on groove shoulder or fitting. Thread burrs may be removed by running a nut onto the thread.

Before installing, lube ring and surface sparingly with a light coat of grease.

Lubing helps eliminate a distorting stretch (causing a leak) and aids ring in seating naturally in groove without wrinkles or twists. Remember, the lube must be compatible with 0-ring material and system fluid.

7-73

I

EM029421-0 (en-us)

In hydraulic systems, flow wash bearing surfaces with hydraulic fluid and wipe parts, if needed ONLY with a dust free cloth.

(

In an oxygen system, DO NOT PERMIT OIL AND GREASE around the 0-ring.

The mixture of oxygen; oil and grease causes an explosion.

INSTAllATION on a piston does require a bit of stretching, but try to keep it uniform. Once installed, remove any and ALL twists. When pushing piston into cylinder, push straight in; DO NOT TURN while pushing. Turning causes bunching and eventually a leak. Most installations are the removal procedure in reverse.

Some installations require the 0-ring to slip over sharp edges, such as screw threads. Cover these edges with think plastic tape or aluminum foil, lube ring and work into place. Perhaps making a thimble of plastic to place over threads first is even easier.

Tape Protects O·ring During Installation

Other installations, such as placing a ring in a positioning type universal fitting, are more involved. In this case, a backup ring is lightly coated with lube and then worked into the A gal nst Boss Boss counterbore of the jam nut. The O·rlng 0-ring is stretched and rolled over fitting threads and into smooth threadless surface designed for the backup and 0-rings. Next, jam nut is pushed firmly against lower threaded section of fitting. Fitting installs in boss until ring contacts boss and increases torque.

Jam nut is held stationary in this position while applying 1-1/2 turns to fitting.

Then turn fitting into boss NOT MORE than ONE added turn to position it. Final step is to hold fitting and torque jam nut properly.

A similar procedure is used for non-positionfittings, but the jam nut and backup ring may be omitted.

BACKUP RINGS provide a firm surface for 0-rings to press against to avoid extrusion, under high pressures, into clearance between sealed surfaces. Any surface movement with 0-ring, so extruded, results in high wear rate which finally leads to ring failure.

Backup rings are needed on each side of an 0-ring when pressure is in alternate directions. Using a single ring, install on the downstream side of the 0-ring.

7-74

(

EM029421-0 (en-us)

"Typical" Application

Scarfed Edge (2 Places)

Single Back-up Ring Without Back-up Ring

/ View 1 (Enlarged)

With Back-up Ring

Teflon backup rings, used on hydraulic systems, have a low friction coefficient and are resistant to most chemicals. They are impervious to oils and solvents and little effected by acids or inorganic salts.

When installing a Teflon backup ring, spiral direction is clockwise with the scarfed ends facing.

For proper and improper techniques, see sketch. In applications where a leather backup ring is needed; the smooth, grained side is placed next to the ring.

Slipper rings are provided to prevent grabbing or seizing of smooth surfaces under high pressure. In cross section, these may be L or U-shaped and plain bands or Teflon. See sketch.

Adifferenttechnique is needed when installing slipper rings as the Teflon material does not deform easily. Often it is necessary to double back the Teflon portion of the high pressure 0-ring assembly. See sketch. Once positioned, this ring must be ironed or worked into shape in the 0-ring groove.

Back-up Rings Correctly Installed on Opposite Sides of a-ring with Back-up Ring Scarfed Ends Staggered

Spiral Back-up

t e::::s

~

Incorrectly Wound Spiral Ring

Spiral Back-up Ring 0-rlng

Correctly Wound Spiral Ring

Here a smooth, nylon tool is needed to prevent scratching and marring the metal and slipper rings.

Bulk storage of 0-rings requires a clean container, sealed and labeled plastic bags, glass or plastic jars or even the original shipping packs. MAINTAIN this cleanliness between storage and the seal gland.

Back-up Rings Scarfed Ends (Staggered)

Piston Head

Spiral Back-up Rings Correctly Installed on Opposite Sides of 0-rlng Ring with Scarfed Ends of Back-up Rings Staggered.

I yplcal U-Shaped Ring of Teflon for Low Breakout & Running Friction

I

U-Shaped Sllppnr Ring Folded Back on Itself for Insertion

L-Shaped Seal on Left, Plain on Right

7-75

Ring Is Straightened In Insert Groove with Cone-pointed Nylon Tool Installation of U-Shaped Seal

I

EM029421-0 (en-us)

TABLE 8

TABLE 7 MODES OF FAILURE FAILURE

GENERAL CONDITION

DECIMAL EQUIVALENTS EXAMPLE

Progressive cutting by corner of piston groove.

Pulsating pressure on 0-Ring.

P~Cut

Progressive cutting as in static packing plus abrasive wear.

Pulsating pressure on 0-Rings.

p~Cut

Knlbblng extrusion.

Rupture of material, large pieces torn off.

Fatigue from shock loads, high temperature, local seizure, pulsating pressure, etc.

Abrasion

Rotation of part or all of clrcu mference of packing In groove. (Sometimes called "spiral failure"

Complete explanatlon not found.

Occurrence not predictable.

Possibly sudden increase In friction on working face.

Axial grooves worn In working surface.

I mperfectlons In cylinder surface.

Particles of dirt, metal, or rubber.

PJD.-

pj10fl Found to occur chiefly when packing was moving In same direction as pressure.

6" Segment of Plan VIew

Axial grooves as above.

Packing totally extrudes thru clearance space.

Rapid passage of all across working face.

Large radial clearance. Soft packing.

See above sketch

PJ),_

INCHES .0156 1/32 - .0312 .0468 1/16 - .0625 .0781 -.0937 3/32 .1094 1/8 - .1250 .1406 5/32 - .1562 .1719 3/16 - .1875 .2031 - .2187 7/32 .2344 1/4 -.2500 .2656 - .2812 9/32 .2969 - .3125 5/16 .3281 11/32 -.3437 .3594 - .3750 3/8 .3906 13/32 - .4062 .4219 - .4375 7/16 .4531 15/32 -.4687 .4844 -.5000 1/2 .5156 17/32 - .5312 .5469 - .5625 9/16 .5781 19/32 - .5937 .6094 - .6250 5/8 .6406 21/32 - .6502 .6719 11/16 - .6875 .7031 23/32 - .7187 .7344 - .7500 3/4 .7656 25/32 - .7812 .7969 13/16 - .8125 .8281 27/32 - .8437 .8594 -:875 7/8 .8906 29/32 -.9062 .9219 15/16 - .9375 .9531 31/32 - .9687 .9843 1 - - - 1.0

(

MILLIMETERS .3962 .7925 -3/64 1.1887 1.5875 -5/64 1.9837 2.3799 -7/64 2.7788 3.1750 -9/64 3.5712 3.9675 - 11/64 4.3663 4.7625 5.1587 - 13/64 5.5550 - 15/64 5.9538 6.3500 - 17/64 6.7462 7.1425 - 19/64 7.5413 7.9375 8.3337 - 21/64 8.7230 -23/64 9.1288 9.5250 -25/64 9.9212 10.3175 -27/64 10.7163 11.1125 -29/64 11.5087 11.9050 -31/64 12.3076 12.7000 -33/64 13.0962 13.4925 - 35/64 13.8913 14.2875 -37/64 14.6837 15.0800 -39/64 15.4788 15.8750 -41/64 16.2712 16.6675 17.0663 - 43/64 17.4625 -45/64 17.8598 18.2550 -47/64 18.6538 19.0500 -49/64 19.4462 19.8425 -51/64 20.2413 20.6375 -53/64 21.0337 21.4230 -55/64 21.8288 22.2250 - 57/64 22.6212 23.0175 -59/64 23.4163 23.8125 24.2087 - 61/64 24.6050 -63/64 25.0012 25.4000

- 1/64

( 7-76

EM029421-0 (en-us)

Keep in mind: Dust is one of the meanest abrasives, mostly since it is hard to see.

Ozone, oxygen and moisture; over a long period of time act on 0-rings also. Most manufacturers now add chemicals to slow or eliminate the effects; but correct storage is stil! needed.

Excessive heat is a problem, so storing 0-rings on the top shelf near the tin roof is not good. Besides that, sunlight and flourescent light tends to age rings earlier. Use Polyethylene or brown glass jars to keep light out.

Contact between rings lying together in bulk or on hooks or pegs damages seal surfaces. When stored in the open, they collect dust and dirt. Also, bulk shipments often cannot be numbered. Keep rings away from steam pipes, heater conduits and areas where contact with water, oils, grease, solvents and other damaging fluids seems likely. Add replacement 0-rings to the bottom or back of a bin as older parts move to the top or front to assure issue before a brand new one.

Individually packaged rings seem to have unlimited shelf life. Some maintenance shops use peg boards for individual packages of shop stock used daily. These are arranged by size on each board, but with ONLY ONE compound type per board.

BASIC THINGS TO REMEMBER:

Select the proper 0-ring ONLY by part number.

0-rings are almost always dimensioned in terms of crosssection diameter and inside diameter either in decimals or fractions.

Example:

Keep all parts clean.

Standard Size Cross Sections

Use compatible fluids and rings.

Actual mm

Nominal Actual (inch)

Use either individual containers or provide LABELED, clean, low light, storage.

1.7780±0.0762 2.6162±0.0762 3.5306±0.1 016 5.3340±0.1270 6.9850±0.1524

1/16 3/32 1/8 3/16 1/4

DO NOT USE hardened steel tools when removing or installing rings.

0.070±0.003 0.1 03±0.0003 0.139±0.004 0.21 0±0.005 0.275±0.006

w-H-

os-1~

-tr+V-L

MAX{):

Be sure new rings are not mixed or contaminated when put into labeled storage.

DO NOT INSTALL a dry 0-ring on a dry shaft.

.003 MAX SECTIONW-W

Standard inside diameters for these various cross sections range anywhere from 1 /32 to 26 inches.

All in all, there are slightly more than 300 standard 0-ring sizes.

7-77

I

EM029421-0 (en-us)

GRID COUPLINGS (Type F and T)

( 1. Mount cover with seal ring and hub on shaft.

Press or shrink hubs on respective shafts so hub face is flush with shaft end. Tighten set screws on BOTH hubs on sizes 3 thru 11.

1

MOUNT COVER, SEAL RING AND HUB ON SHAFT

2. Check gap and angular alignment. Set coupling for normal gap. Align shafts by placing spacer block equaling gap between hub faces, and at right angles to it. Check using feelers.

2

GAP AND ANGULAR ALIGNMENT

Maintain normal coupling gap where possible. To insure best performance, DO NOT EXCEEDminimumandmaximumgaps.Consult company if limited axial float is needed.

Provide for shaft end play in coupling gap when using sleeve bearing units. Once mounted, position free unit so coupling gap is between minimum and maximum limits with BOTH shafts in extended or retracted position. With gap set and shafts aligned, tighten unit foundation bolts and RECHECK alignment.

3. Check parallel alignment so a straight edge rests squarely on BOTH hubs at right angles. Fasten foundation bolts and RECHECK alignment and gap.

3

7-78

OFFSET ALIGNMENT

EM029421-0 (en-us)

4. Once aligned, carefully insert gasket between hubs and hang it on either hub. DO NOT DAMAGE gasket. Force as much lube as possible into gap and gridmember grooves.

4

INSERT GASKET AND LUBRICATE

5. Insert grid member. Coupling sizes 3 thru 11 use a single layer grid, painted aluminum.

Size 12 thru 190 use a two layer grid with the inner layer painted aluminum and stamped IN while the outer layer is painted bronze and stamped OUT. lnstallation-Gridmember rungs, truly radial, need spreading slightly to pass over coupling tooth at its O.D. To do this with minimum spreading, start grid at either end and tap rungs only part way into grooves.

Once all rungs are partially into respective grooves, tap grid all the way in. When installing a two layer grid, center the outer layer sections over free ends of inner layer.

5

INSERT GRID

Removal-A round rod or screwdriver of a size to easily fit into open loops ends of grid is all that's needed. Begin at open end of grid section and insert rod into loop ends. Use next tooth as a pry point and pry grid out radially, in EVEN and gradual stages. Proceed alternately from side to side, lifting grid about halfway out until end of grid is reached. By repeating same steps again, grid clears teeth.

6. Pack spaces between and around grid with as much lube as possible. Scrape or wipe excess lube off flush with grid. Lightly oil hubs to ease sliding covers onto hubs.

6

PACK WITH LUBRICANT

7-79

EM029421-0 (en-us)

7. Position covers so that lube fittings are 180 degrees apart. Align covers to prevent wobble. Tighten cover bolts. Check seals for proper seat. Insert thin, smooth screwdriver under seal for venting when lubing with permanent fittings.

Lube until grease flows thru coupling and out other hole. Then RE-INSTALL BOTH LUBE PLUGS.

1

(

ASSEMBLE COVERS

Stamped

11

0UT"

Stamped

11

IN"

3

1

3 1.

Seal Rings are identical.

2.

Cover Halves are furnished with permanent lube fittings or, in some sizes, 1/8" or 3/8" NPT holes to receive your lube fittings.

Cover halves are interchangeable and otherwise 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.

5.

Gasket fits between the covers and prevents grease leakage.

LUBRICATION OF COUPLING

DURING ASSEMBLY

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

( 7-80

EM029421-0 (en-us)

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.

IMPROPERLY FILLED- Note the large number of air pockets and the absence of lubricant in the gap and at the inside diameter of the cover.

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

Riling of gap has been neglected numerous air pockets.

7-81

TABLE 9 PERMISSABLE COUPLING MISALIGNMENT AND END FLOAT Gridmember Data

EM029421-0 (en-us) INCHES (mm) POUNDS (Kg)

DO NOT APPLY LOAD UNLESS COMPLETE GRIDMEMBER IS INSTALLED AND ALL SECTIONS IN THEIR PROPER LAYER :jj: C)

Grid member Dimensions Inches (mm)

:§G)

C..!::!

i5(/)

0

Ul C)

c:

:::1

a:

:jj:

!!!

G)

>.

m

...J

:jj:

"EG) G)...

E>Clm (I) ....I

(/)

3

.048x3/16x1 1 /2

20

1

1

4

1/16x3/16x2 (1.6)x(4.8)x(50.8) 1/16x1/4x2 (1.6)x(6.4)x(50.8) 1/16x1/4x2

24

1

1

28

1

1

32

1

1

36

1

2

40

1

2

40

1

2

40

1

.2

40

1

2

44

2

2

52

2

2

48

2

2

48

2

2

56

2

2

5 6 7

16

1/16x3/8x2 (1.6)x(9.5)x(50.8) 3/32x3/8x2 1/4 (2.4)x(9.5)x(57.2) 3/32x1 /2x2 3/4 (2.4)x(12.7)x(69.9) 1 /8x1 /8x3 1/2 (3.2)x(3.2)x(88.9) 1 /8x1 /2x3 1/2 (3.2)x(12.7)x(88.9) 1 /8x5/16x3 1/2 (32)x(7.9)x(88.9) 1 /8x3/16x3 1/2 (3.2)x(4.8)x(88.9) 5/32x3/8x4 1 /2 (4.0)x(9.5)x(114.3) 3/16x3/8x4 1/2 (4.8)x(9.5)x(114.3) 3/16x3/8x4 1/2

17

3/16x3/8x4 1/2

64

2

2

18

3/16x3/8x4 1 /2

72

2

3

190

3/16x1 /2x6 3/4 (4.8)x(127)x(171.45)

72

2

4

8 -....!

I 00

9

1\)

10 11 12 13 14 15

Angular

Outside Diameter

Ul

Single Layer Aluminum Inch (mm)

Outer Layer Bronze Stamped "Out"

Inner Layer Aluminum Stamped "In"

2.375 (60.325) 2.687 (68.25) 3.125 (79.38) 3.625 (92.08) 4.250 (1 07.95) 5.000 (127.0) 5.500 (139.7) 6.125 (155.58) 6.750 (171.45) 7.500 (190.50) 8.750 (222.25) 9.500 (241.30) 9.750 (247.65) 11.250 (285.75) 12.750 (323.85) 14.250 (361.95) 15.750 (400.05)

6.875 (174.63) 8.125 (206.38) 8.750 (222.25) 9.000 (228.6) 10.500 (266.70) 12.000 (304.08) 13.500 (342.90) 14.750 (374.65)

-tifj-

Parallel

End Float

NOTE 1

~ 1fl]f

.005 (.127) .005

.005 (.127) .005

.005

.005

.005

.005

.005

.005

.010 (.2540) .010

.010 (.2540) .010

.010

.010

.010

.010

.012 (.3048) .012

.012 (.3048) .012

.012

.012

.012

.012

.012

.012

.012

.012

.012

.012

.015 (.381)

.015 (.381)

---!I+-

'

GAP MIN

MAX

-'

5/32 (.006) 3/16 (4.763) 3/16 (4.763) 3/16 (4.763) 3/16 (4.763) 1/4 (6.35) 1/4 (6.35) 3/8 (9.525) 3/8 (9.525) 3/8 (9.525) 3/8 (9.525) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7)

1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6) 1/16 (1.6)

1/8 (3.2) 1/8 (3.2) 1/8 (3.2) 1/8 (3.2) 1/8 (3.2) 1/8 (3.2) 1/8 (3.2) 3/16 (4.8) 3/16 (4.8) 3/16 (4.8) 3/16 (4.8) 1/4 (6.4) 1/4 (6.4) 1/4 (6.4) 1/4 (6.4) 1/4 (6.4) 1/4 (6.4)

5/32 (4.0) 3/16 (4.8) 3/16 (4.8) 3/16 (4.8) 3/16 (4.8) 1/4 (6.4) 1/4 (6.4) 3/8 (9.5) 3/8 (9.5) 3/8 (9.5) 3/8 (9.5) 1/2 (12.0) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7)

lb (kg)

4 (1.8) 6 (2.7) 8 (3.6) 10 (4.5) 14 (6.3) 28 (12.6) 33 (14.9) 49 (22.1) 60 (27.0) 75 (33.8) 97 (43.7) 145 (65.3) 175 (78.8) 215 (96.8) 285 ( 128.3) 365 (164.3) 650 (292.5)

Lube Req. lb (kg)

measured difference in gap of points 180° apart. Value indicated is total distance measured at outer extremity of hub.

C)

.5

G)

ii.!::!

5(/)

0

1/16 3 (.03) 4 1/16 (.03) 5 1/8 (.05) 1/8 6 (.05) 7 1/8 (.05) 1/4 8 ( .1) 1/4 9 ' (.1) 10 3/8 (.17) 1/2 11 (.2) 12 5/8 (.3) 3/4 13 (.3) 14 1 1/2 (.7) 1 1/2 15 (.7) 2 16 (.9) 2 3/4 17 (1.2) 3 1/4 18 (1.5) 7 190 (3.2) ~

--" Note 1: "X'

NORM

WT

EM029421-0 (en-us)

FALK STEELFLEX COUPLINGS TYPE T10-SIZES 150 THRU 260

8

SIZES 240 thru 260

SIZES 150 thru 230 PART NUMBERS 1. Seal 2. Cover 3. Hub (Specify bore and keyway) 4. Grid 5. Gasket

6.

7.

8.

9.

Fasteners, Cover Lube Plug Seal Retainer Fasteners, Seal Retainer

INTRODUCTION- These instructions apply to Sizes 150 thru 260 T10 Falk Steelflex Tapered Grid Couplings. They are designed to operate in either the horizontal or vertical position without modification. The performance and life of the couplings depend largely upon how you install and service them. Carefully follow the instructions for optimum performance and trouble free service.

PARTS IDENTIFICATION-All coupling parts have identifying part numbers as shown above. Parts 3 and 4 (Hubs and Grids), are the same for both T1 0 and T20 couplings; all other coupling parts are NOT INTERCHANGEABLE. Therefore, when ordering parts, always SPECIFY SIZE and TYPE shown on the COVER.

7-83

EM029421-0 (en-us)

LUBE FITTINGS-Cover halves have 3/8 NPT lube holes. Use a standard grease gun and lube fitting.

(

LUBRICATION-Adequate lubrication is essential for proper operation of the coupling. Refer to Installation Data Table for the amount of lubricant required. It is recommended that the coupling be checked once a year and lubricant added if required. For extreme or unusual operating conditions, check more frequently.

LUBRICANT SPECIFICATIONS-Refer to Falk Manual428-010for recommended lubricants. The following specifications apply to lubricants for Falk couplings which are lubricated annually and operate within ambient temperatures of 0 degrees to 150 degrees F (-18 degrees to +66 degrees C). For temperatures beyond this range, consult the MPSD Service Representative.

DROPPING POINT -300 degrees F (149 degrees C) or higher.

CONSISTENCY -NLGI No.2 with worked penetration value in the range of 250 to 300.

SEPARATION and RESISTANCE-Low oil separation rate and high resistance to separation from centrifuging.

LIQUID CONSTITUENT-To possess good lubrication properties equivalent to a high quality, well refined petroleum oil.

INACTIVE-Must not corrode steel or cause swelling or deterioration of synthetic seals.

CLEAN-Free from foreign inclusions.

SEMI-PERMANENT LUBRICATION-Up to eight years between lubrication checks may be obtained thru the use of "still-bottom" asphaltic based lubricants. Refer to Falk Service Manual 428-012 for details.

INSTALLATION-Only standard mechanics tools, wrenches, a straight edge and feeler gauge are required to install Falk Steelflex couplings. Couplings are furnished for an INTERFERENCE FIT without set screws. Heat hub in an oil bath to a maximum of 275 degrees F ( 135 degrees C) to mount. Oil flash point must be 350degrees F ( 177 degrees C) or higher. Detailed mounting instructions follow:

7-84

(

EM029421-0 (en-us)

1

MOUNT SEALS AND HUBS

Lock out starting switch of prime mover.

Clean all metal parts using a non-flammable solvent. Lightly coat seals with grease and place on shafts BEFORE mounting hubs. Mount hubs on their respective shafts so the hub face is flush with the end of its shaft.

2

GAP AND ANGULAR ALIGNMENT

Use a spacer bar equal in thickness to the normal gap specified in Table. Insert bar, as shown at left, to same depth at 90 degrees intervals and measure clearance between bar and hub face with feelers.

The difference in minimum and maximum measurements must not exceed the ANGULAR limit specified in Table.

3

OFFSET ALIGNMENT

Align so that a straight edge rests squarely (or within limits specified in Table) on both hubs as shown at right and also at 90 degree intervals. Check with feelers. The clearance must not exceed the OFFSET limit specified in Table. Tighten all foundation bolts and repeat Steps 2 and 3. Realign coupling if necessary. NOTE: Use a dial indicator for more accurate alignment.

7-85

I

EM029421-0 (en-us)

4

INSERT GRID

Pack gap and grooves with specified lubricant before inserting grid. Install grid segments so that all cut ends extend in the same direction, this will assure correct grid contact with non-rotating pin in cover halves. Spread grid segments slightly to pass over the coupling teeth and seat with a soft mallet.

5

(

PACK WITH GREASE AND ASSEMBLE COVERS

Pack the spaces between and around the grid with as much lubricant as possible and wipe off excess flush with top of grid. Position seals on hubs to line up with grooves in cover. Move lower cover half into position and block-up in place.

Sizes 150 thru 230- Position gaskets on flange split and assemble upper cover half with the match mark on the same side as the lower half (see above). Secure cover with fasteners and tighten to torque specified in Table. CAUTION: Make certain all lube plugs are installed before operating.

INTERNAl PIN

0

0 0 0 0

Sizes 240 thru 260-Check all flange faces for burrs and coat either half with Permatex No.2 or equivalent. Assemble upper cover half with the internal pin (see drawing at right above) on same side as the lower half. Secure cover with fasteners and tighten to torque specified in Table. Assemble split seal retainers so the split is 90 degrees from the cover split. Secure with fasteners. CAUTION: Make certain all lube plugs are installed before operating.

( 7-86

EM029421-0 (en-us)

INSTALLATION DATA* (Dimensions-Inches)

.062 .062 .062 .062

Operating& Cover Max Alignment Limits Bolt Speed Offset Angular Torque (rpm) NorMax (Max) (Max) (lb-in) mal 650 1500 .015 .015 .250 .500 .250 .500 .015 .015 650 1350 .250 .500 .015 .015 1300 1225 .250 .500 .015 .015 1300 1100

.062 .062 .125 .125 .125 .125 .125 .125

.250 .250 .500 .500 .500 .500 .500 .500

Gap

SIZE Min

ISOT 160T 170T ISOT 190T 200T 210T 220T 230T 240T 2501

260T

.500 .500 .750 .750 .750 .750 .750 .750

.015 .015 .020 .020 .020 .020 .020 .020

.015 .015 .020 .020 .020 .020 .020 .020

1300 2300 2300 3580 3580 5350 5350 5350

1050 900 820 730 680 630 580 540

Lube Wt (I b)

4.2 6.2 7.7 8.3 9.7 12.4 25 35 55 75 110 150

*Refer to Bulletin 421-110 for maximum bores and Engineering 427-108 for rebaring instructions.

• Align couplings within "Operating Alignment Limits" specified above. Exceeding these limits reduces coupling life and the maximum speed stated.

6 PERIODIC LUBRICATION-Remove all lube plugs and insert lube fitting.

Fill with recommended lubricant until an excess appears at an open hole; then insert plug. Continue procedure until all plugs have been inserted. CAUTION: Make certain all plugs have been inserted after lubricating.

COUPLING DISASSEMBLY AND GRID REMOVAL Whenever it is necessary to disconnect the coupling, remove the cover halves and grid. A round rod or screw driver that will conveniently fit into the open loop ends of the grid is required. Begin at the open end of the grid section and insert the rod or screw driver into the loop ends. Use the teeth adjacent to each loop as a fulcrum and pry the grid out radially in even, gradual stages, proceeding alternately from side to side.

7-87

EM029421-0 (en-us)

(

GEAR COUPLING TYPE G AND GV G TYPE INSTALLATION (HORIZONTAL)

HORIZONTAL Types GlO and 20

VERTICAL Types GVlO and 20

l~::

2

cJ;-_23

20. GV Flex Hub 1. Seal Ring 2. Flanged Sleeve 3. G Flex Hub

4. Gasket 5. Lube Plug 6. Bolt, Nut, Lockwasher

(Specify Bore and Keyway)

21. Center Plate 22. Thru51 Button 23. Thrust Plate

Parts 1, 2, 4, 5 and 6 shown at the left complete the balance of the coupling.

(Specify Bore and Keyway)

1. Clean all parts. Heat hubs in an oven or use suitable dry heat. DO NOT rest gear teeth on container bottom or apply a flame directly to gear teeth.

Pack sleeve teeth with grease and lightly coat seals with grease BEFORE assembly. DO NOT use cup grease. DO NOT DAMAGE SEALS. Use a dial indicator to align dynamically balance couplings and assembly parts with mating match marks aligned. Mount indicator on one hub and take readings for OFFSET check on O.D. of other hub. The difference between minimum and maximum readings DIVIDED by two should not exceed the values in Table. For ANGULAR check, take readings on either face of other hub. The difference between the minimum and maximum readings should not exceed the values in Table.

2. MOUNT FLANGED SLEEVES, SEAL AND HUBS-Place flanged sleeves WITH seal rings on shafts before mounting hubs.

CAUTION: DO NOT DAMAGE SEALS. Mount hubs on respective shafts, as shown so each hub is flush with its shaft end. Position equipment in approximate alignment with approximate gap specified in Table 10.

NOTE: longer shank toward gop end.

2

MOUNT FLANGED SLEEVES, SEALS AND HUBS

(

7-88

EM029421-0 (en-us)

Always measure to some depth,

3

GAP AND ANGULAR ALIGNMENT

3. GAP AND ANGULAR ALIGNMENT -Use a spacer bar equal in thickness to gap specified in Table. Insert bar, as shown, to same depth at 90 degrees intervals and measure clearance between bar and hub face with feelers. The difference in minimum and maximum measurements should NOT exceed the ANGULAR limit specified in Table.

4. OFFSET ALIGNMENT -Align so that a straight edge rest squarely on both hubs as shown and also at 90 degree intervals. Check with feelers. Clearance should NOT exceed OFFSET limit specified in Table. Tighten ALL foundation bolts and repeat steps 3 and 4. Realign coupling if necessary.

Grease hub teeth.

5

INSERT GASKET AND JOIN FLANGED SLEEVES

4

OFFSET ALIGNMENT

5. INSERT GASKET AND JOIN FLANGED SLEEVES-Insert gasket, DO NOT DAMAGE GASKET, between flanges. Position flanged covers with lube holes at 90 degrees and draw flanged cover into position. Use bolts, nuts and lockwashers furnished with couplings. IMPORTANT: Tighten flange bolts and nuts to torque specified in Table.

6. LUBRICATION-Fill with grease until excess appears at an open hole; then insert plug. Continue procedure until all plugs have been inserted. IN ADDITION, vent TOP flanged sleeve by inserting a 0.010 inch thick SMOOTH feeler gauge between seal and hub. Fill until excess appears at feeler. Repeat at 90 degree intervals.

CAUTION: INSERT ALL plugs after lubricating.

7-89

LUBRICATE

EM029421-0 (en-us)

GEAR TYPE COUPliNG INSTALLATION (VERTICAL)

gap

'

.

'

'""

./I

MOUNT FLANGeD SLEEVES, SEALS AND HUBS

B. INSTALL THRUSTPLATEINLOWERHUBTap thrust plate into counterbore until fully seated and stake in place. Position equipment. Refer to Steps 3 and 4.1MPORTANT: With coupling aligned, pack lower flanged sleeve with grease and correctly position sleeve and gasket DO NOT DAMAGE GASKET.

Thcu>l~ Plate.~

t .J I L I

-~, B

end.~ I

A

•

(

NOTE: Longer shank toward

A. MOUNT FLANGED SLEEVES, SEALS AND HUBS-Refer to step 1. Place flanged sleeves WITH seal rings on shafts BEFORE mounting hubs. DO NOT DAMAGE SEALS. Mount hubs on respective shafts, as shown, so counterbore face is flush with shaft end.

-

INSTALL THRUST PLATE IN LOWER HUB

C. INSERT CENTER PLATE WITH THRUST ·BUTTON DOWN-Insert center plate with THRUST BUTTON DOWN. Center plate in counterbore of lower flanged sleeve. I MPORTANT: Pack upper hub teeth with grease and then complete assembly per Steps 5 and 6.

Insert center plate

with thrust

button DOWN.

Pump grease into

BOTH top and bottom sleeves.

(

INSERT CENTER PLATE WITH THRUST BUTTON DOWN

MAINTENANCE-Lubricate couplings at least once every six months. Lubricate more frequently when exposed to excessive moisture, extreme temperatures, rapid reversing or shock loads or excessive misalignment.

TABLE 10 COUPliNG INSTALLATION DATA Coupling Size GAP (Hub Separation)

G

in(mm)

cw

10

15

20

25

30

35

40

45

50

55

60

70

1/8 (32)

1/8

1/8

3/16

3/16

1/4 (6.5)

1/4

5/16 (8)

5/16

5/16

5/16

3/8 (9.5)

7/16

7/16

7/16

9/16 (14.5)

9/16

1 1/16 7/8 (27) (22)

1 (26)

1 (26)

1 (26)

1 1/8 (29)

1 3/8 (35)

.010

.012

.012

.012

.012

.012

.012

.012

.020

.020

.020

.030

.030

.030

(4.8)

(11.5) Operating

Offset Angular

in(mm) Grease-lbs (kg)

G

Torque in/lb Nm

G&GV 20 Flange

.005

.005

Torque in/lb Nm

.010

.005

.010

.012

.305

.254

.127

GV G&GV 10 Flange

.005 .127

Alignment

.010

.254

.015

.015

.381

.762

.508

1/16

1/8

3/8

1/2

3/4

1

1 3/4

2 3/8

3 1/2

4 1/4

7 5/8

14

.03

.05

.17

.2

.3

.5

.8

1.1

1.6

2.0

3.4

6.3

1/8

1/4

1/2

3/4

1 3/8

2 3/8

3

5 1/4

6 3/4

8 1/2

.05

.1

.2

.3

.6

1.1

1.4

2.4

3.8

5.0

95

170

170

420

420

845

845

845

3.0 1490

1490

--

--

107

192

192

474

474

954

954

1682

85

145

1290

1290

1430

1430

2160

164

720 813

720

96

360 406

954 ' 1682 1290 1430

813

1456

1456

1456

1614

1614

2438

7-90

1614

11 1/4 231/8 10.5

(

\

EM029421-0 (en-us)

MOTOR-GENERATOR KEYLESS COUPLINGS (Draglines Only) ASSEMBLY Assembly of Keyless Couplings requires heating coupling uniformly in an oven (DO NOT unevenly heat with a torch) to a temperature of 392 degrees F. or 200 degrees C., and shrinking onto a cylindrical shaft extension with no key or keyway. The amount of interference fit sufficiently gives adequate driving torque with adequate safety factor, using no key.

When reinstalling a removed coupling half, locate it in the original axial and angular position. Generally, axial position is when the hub end is flush with the shaft end. Space the pressure hole in the shaft as far as possible from the pulloff holes. Check the face of a solid coupling and insure it is perpendicular to the shaft. Check the periphery of the coupling and insure it is concentric with the shaft. If necessary, true up these surfaces. Perform these checking and truing operations with shaft accurately aligned in a lathe.

REMOVAL Removal of Keyless Coupling uses hydraulic pressure applied to the circumference of groove C in shaft extension S. (See sketch on following pages for cutaway of section for removal). When this pressure exceeds initial radial stress, due to interference fit, coupling hub H expands a small amount and allows oil to seep into the fit in both directions from groove C. Although the distance from groove C to coupling face A is less than distance to face 8, the end effect at corner maintains hydraulic pressure until entire bore length expands and oil appears at face B. Upon reaching this condition (3 or 4 minutes after applying pressure) the coupling floats on a high pressure oil film and may be removed with a hand puller and wrench. When coupling face 8 uncovers groove C, oil pressure is instantly lost. The coupling now pulls harder to shaft end. However, this area is small enough that finishing with same wrench and puller adding a little more force does the job.

Protect the shaft center from damage with a small brass or copper shim under puller driving point.

A

WARNING: DO NOT USE ORDINARY PIPE FITTINGS. PRESSURES INVOLVED WEll ABOVE RUPTURING STRENGTH OF ORDINARY PIPE AND FITTINGS.

Use threaded holes near shaft for pulling coupling. Distortion of coupling is possible when pulling near the outer rim.

7-91

EM029421-0 (en-us)

If coupling removal is difficult using this procedure (bores or shaft surfaces abused) the following tips may help.

(

If oil does not appear on both hub ends due to insufficient pressure (excessive shaft end leaks), use heavier oil or grease. Slight, cautious peening around leak helps.

SPECIAl TOOLS Pressure Equipment, such as a Blackhawk pump, connects to groove C by high pressure flex hose L, high pressure elbow K and high pressure nipple J. This nipple J is long enough for hub to pull clear of shaft extension and not interfere with elbow or hose. The nipple J also supports coupling when it drops free. The nipple screws into a pipe tap in the shaft end which connects to groove C thru two drilled holes G.

A

J

K

s

SPECIAl TOOL APPLICATION 7-92

(

EM029421-0 (en-us)

Unless otherwise called for, replacement coupling's have a finished bore and 1/64 inch of material on face, rabbet diameter and 0.0. to be removed after assembly on shaft.

Keyed couplings usually have an interference fit of .0005" to -001" per inch of diameter.

Keyless couplings need an interference fit of .001" per inch of diameter.

Measure the rabbet diameter and finish machined surfaces to match mating half coupling using fit from line to line to .001 inch interference. (See sketch.)

3/16" 1/32"

Finished dimensions given, but 1/64" allowed to finish these surfaces after assembly on shaft.

A Dia. 1/32" x 45° Cham

\

B Dia.

/

T

T

Bore Dia.

Bore Dia. Male

Female

TOLERANCE FINISH BORE Checking Coupling Alignment requires secure bolting of M-G set base to deck in operating position. Follow the step by step procedure and accurately record ALL readings. This is important. When checking more than one M-G coupling, always start at coupling nearest the two-bearing unit, (usually the motor.)

THE SOLIDLY COUPLED SETS PROCEDURE IS: 1. Loosen ALL coupling bolts to point they do not hold halves together.

2. Start at coupling at two-bearing unit (usually the motor) or near middle of a long set. Two diametrically opposed bolts need careful adjustment to be loose and YET NOT ALLOWED coupling rabbet to disengage. Spread coupling about .005 inch to .015 inch using two jacking screws or with a fiber mallet, rap the flange.

7-93

EM029421-0 (en-us)

3. Measure gap between coupling faces at four points (90 degrees around coupling rim) with feeler gauge to nearest .001 inch. Maximum variation may not exceed .002 inch between any two readings.

4. Rotate coupling 90, 180, 270, 360 degrees and take similar readings. Maximum variation may not exceed .002 inch.

5. Correct horizontal misalignment by loosening foot bolts, removing dowel pins and bumping frame into position. Correct vertical misalignment by shimming under feet. Check and maintain ALL internal clearances (air gaps, bearing covers, fans, baffle clearances) equally around circumference. Abuse in shipping and handling often causes misalignment, even distort dowel pins to point of needing redoweled.

6. Repeat steps 2, 3, 4, 5 for each coupling while working away from two bearing unit.

7. Recheck couplings of long sets after completing previously mentioned checks, due to possibility that shimming on previous units effects units already checked. After aligning set within specified limits, carefully tighten ALL coupling bolts.

TORQUE VALUES Recommended torque values for tightening coupling bolts: 3/4 inch bolts-500 ft./lbs. and for 1 inch bolts-770 ft./lbs.

7-94

/ \

\

EM029421-0 (en-us)

25,000 HOUR DRAGLINE MAINTENANCE INSPECTION SCHEDULE The following maintenance schedule is based on a typical Marion 8000 series dragline. Certain machine features or configurations may be different on a specific machine. Please review carefully and note any such differences.

If you have any questions, refer to the appropriate section of the Maintenance and Operating Manual (these are specific to each machine) or contact your Marion service representative for assistance.

MARION POWER SHOVEL DIVISION-DRESSER INDUSTRIES, INC. USA. Printed in USA

\

EM029421-0 (en-us)

DAILY - EVERY 24 HOURS

(

/·

\

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE VISUAL CHECK POINTS DAILY - EVERY 24 HOURS

MODEL

SIN

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

SHIFT

1

2

3

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

OPERATOR INSPECTOR

DESCRIPTION

STATUS YES

ACTION I REMARKS

NO

2. All Gear Cases

D D D D

3. Brakes for all Motions

D D

Check operation with manual valve.

4. Wire Rope on Hoist and Drag Drum

D D

Pay out rope/inspect drums grooving and rope clamps.

5. Air System

D D

Check anti-freeze level, lubricator oil levels, line filters (liquid/dirt).

6. Compressor(s)

D D

Check sump oil level and drain tank moisture. Check tank pressure-shut off 130 psi; turn on 100 psi.

7. Auto Lube System

D D

Check supply in drums. Verify control valve operation. Check warning/reset circuits. Veryify pump cycle timing/shutoff.

8. Structural Components

D D

Check backleg/boom apex.

Pressure gauges- check tension of backleg safety cable.

9. Lighting System

Check all working lights.

10. Filter Fans

D D D D

11. Main Transformer(s)

D D

Check oil level site gauge.

12. Motor Generator Set(s)

D D

Check site gauge for bearing lubricant.

13. Power Control Room

D D

Verify air conditioning operational.

1. Walkways and Ladders

Keep clear and clean Check oil levels and general condition of all cases, oil circulation system and filter condition as required.

Check bleed duct fan operation and filter fan operation for noise or vibration.

3.

\ EM029421-0 (en-us)

DAILY- EVERY 24 HOURS

---® (o .

\

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE VISUAL CHECK POINTS DAILY- EVERY 24 HOURS

MODEL

SIN

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

SHIFT

1

2

3

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

OPERATOR INSPECTOR

DESCRIPTION

STATUS YES

ACTION I REMARKS

NO

14. Bucket -

Hoist Chain -

Upper/Lower

D D

Check links for twist cracks.

and

15. Bucket -

Drag Chain -

Upper/Lower

D D

Check links for twist cracks.

and

16. Bucket- Wire Rope Sockets/Connections

D D

Check condition of rope and connections.

17. Bucket- Spreader Bar Assemblies- Upper and Lower

D D

Check for cracking.

18. Bucket -

Trunnion Connect Points

Check for cracking RH and LH.

19. Bucket -

Dump Rope Rigging

D D D D D D D D

20. Bucket- Wire Rope Dump Line 21. Bucket -

Arch Structure

22. Bucket -

Corner Castings

23. Bucket- Lip Casting 24. Bucket -

Teeth

25. Bucket Wear Plates

D D D D D D D D

Check condition of chain.

Check condition of anchor.

Check for cracks.

Check for cracks.

Check for cracks.

Identify missing and replace.

Check material remaining.

Check wear.

27. Basket Structure

D D D D

28. Lubrication -

D D

Verify distribution.

26. Bucket Heel Casting

Bucket Rigging

Check for cracks.

5.

EM029421-0 (en-us)

DAILY - EVERY 24 HOURS

(

0

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE OPERATIONAL CHECK POINTS DAILY- EVERY 24 HOURS

MODEL

SIN

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

SHIFT

1

2

3

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

OPERATOR INSPECTOR

DESCRIPTION

STATUS

ACTION I REMARKS

YES NO OPERATOR'S CAB

D D

Check phone and groundman communications signal system.

D D D D D

D D D D D

Check warning systems, lights and alarms.

10. Gearing- All Open Gear Systems

D D D D

D D D D

11. Motor Generator/ Exciter Sets

D D

Check commutation on M-G sets, report excessive arcing.

12. Air System

D D

Check for leaks in air system.

D D D D

Check for leaks in lube system.

1. Phone

2. Safety Systems/Warning Lights 3. Windshield/Wipers 4. Propel Shoe Positioner Gauge 5. Operator Controls 6. Operator's Seat

Check wipers and cab glass window seals.

Check propel shoe positioner gauge operation.

Check all operator controls.

Check proper operation.

MACHINERY HOUSE

7. Main Transformer Temperature Gauge 8. Gears, Cases/Shafting 9. Filter Fans

13. Lubrication System 14. Power Control Room !5. House Structures 16. Winches

D D D D

Check main transformer oil temperature gauge.

Check vibration to identify loose bolts, temperature.

Check/listen to filter fan operation.

Listen and report any unusual noise, vibration. Check bearings, c-enter journal, hoist/drag machinery for over temperature.

Check all electric meters for normal readings_ Check for structural cracks and report location.

Check winch operation.

7.

EM029421-0 (en-us)

DAILY - EVERY 24 HOURS

(

8.

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE OPERATIONAL CHECK POINTS DAILY - EVERY 24 HOURS

MODEL

SIN

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

SHIFT

1

2

3

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

OPERATOR INSPECTOR

DESCRIPTION

STATUS YES

ACTION I REMARKS

NO

FRONT END

17. Boom

D D

Inspect all components/structures and observe excessive boom movement.

18. Intermediate Boom Support Ropes

D D

Check load distribution and slack.

19. Fairlead Assembly

D D

Check tracking and snubber action.

20. Sheaves -

All

D D

Check tracking and bearing heat.

21. Bucket Rigging

Check dump action.

22. Lubrication Hoist & Drag Ropes

D D D D

23. Rope Dampers

D D

Inspect anchor pins/rope retention.

24. Open Gearing

D D

Inspect for cracks and lubricant coating.

25. Gear Case, Pedestals & Bushings

D D

Check for cracks, bushing temperature on long walks.

26. Walking Arm/Shoes/Links

D D

Check for cracks.

27. Open Gearing

D D

Inspect for leaks/cracks and lubricant coating.

28. Gear Alignment

D D

Listen for vibrations or abnormal sounds.

29. Bearings, Shafts

D D

Check by touch temperature.

Auto lube operation.

PROPEL MECHANISM

HOIST /DRAG MACHINERY

9.

EM029421-0 (en-us)

WEEKLY - EVERY 150 HOURS

@

(

(

10.

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE OPERATIONAL CHECK POINTS WEEKLY - EVERY 150 HOURS

MODEL

SIN

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

SHIFT

1

2

3

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

OPERATOR INSPECTOR

DESCRIPTION

STATUS

ACTION I REMARKS

YES NO

1. Air Compressor V-Belts 2. Air Compressor Intake Filter 3. Autolube Systems Operation 4. Swing Gear Cases

D D D D

D D D D

6. All Motion Brake(s)

D D D D

7. Center Journal

D D

5. Hook Shoe Rail Clearance

8. Swing Pinions/Gear Segments 9. Rails/Rollers 10. Boom 11. Intermediate Support Rope 12. Hoist Rope Deflector Sheave 13. Boom Point Sheaves

D D D D D D D D

D D D D

16. Boom Support Ropes

D D D D D D

17. Boom Lights

D D

14. Boom Point Torsion Bar Assemblies 15. Boom Automatic Lube Injectors

18. Boom Structure 19. Boom Jib Crane

20. Tri Structure 21. Main and Intermediate Support Ropes 22. Tri-Structure Sheaves

D D D D D

D D D D D

Tighten and adjust.

Clean.

Check leaks.

Shutdown oil circulating systems. Clean filter traps. Check for leaks.

Inspect, readjust to % in.

Check operation and readjust accordingly.

Check clearance with tub bearing and lock bar.

Check mesh and bolts.

Check I ubrication, bushings and rods.

cages

Climb and inspect.

Check socket and lube.

Check bearing and lube.

Inspect sheave condition, all bolts and dust boot.

Check wear.

Check and identify leaks.

Check condition of connectors and lube.

Check wiring runs and general condition.

Check pipe lacing for cracks.

Check operation.

Climb and inspect.

Check all connectors and lube.

Check tracking and bearings.

11.

EM029421-0 (en-us)

WEEKLY - EVERY 150 HOURS

12.

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE OPERATIONAL CHECK POINTS WEEKLY - EVERY 150 HOURS

MODEL

SIN

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

SHIFT

1

2

3

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

OPERATOR INSPECTOR

DESCRIPTION

STATUS YES

ACTION I REMARKS

NO

Verify operation of injectors.

24. Electrical Cable Runs (Not Shown)

D D D D

25. Backleg Connection and Structure

D D

Check pins.

Climb to inspect.

32. House Filter Units

D D D D D D D

33. Filter Unit V-Belt Drive

D D

Check and adjust as required.

34. Filter Unit Motor Bolts

D D

Tighten as required.

D D D D

Check for bearing noise.

23. Rope Lube and Autolube System(s)

26. Fairlead 27. Fairlead Snubber Adjustment 28. Fairlead Sheaves 29. Rope Lube and Autolube System 30. Structure Condition 31. Bucket

35. Filter Unit Fan 36. Filter Unit Structure 37. Auxiliary Winches 38. House Cranes 39. Power Control Room and Electrical Cabinets (Qualified Individual Only) 40. Electrical Contactors (Qualified Individual Only) 41. Electrical Limit Switches 42. Hoist/Propel Transfer Switch 3. Cable Routings (Not Shown) 44. M-G Set Brushes and Commutators 45. M-G Set Motors Generators Exciters

D D D D D D D

D D D D

Check condition.

Measure band thickness.

Check bearing and lube.

Verify operation of injectors.

Check for cracks.

Clean and inspect condition.

Climb to house roof and inspect general condition.

Check for cracks.

Operate and lubricate.

Operate, check rail system and lubricate.

D D

Check general condition of wiring and operation of all latches.

D D

Check operation/excess arc.

D D D D D

Verify operation.

D D D D D

Verify operation.

Check for frayed insulation.

Verify contact, identify arcing.

Clean with air.

13.

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE OPERATIONAL CHECK POINTS

MODEL

SIN

r----sH-IF-T--1--2--3-( ~------------------~

OPERATOR

PERPETUAL WEEKLY ROUTINE

INSPECTOR DESCRIPTION

STATUS

ACTION I REMARKS

YES NO 1. WEEK 1 THRU 4 - Tub, Swing Segments,

Swing Pinions Retainer and Lower Roller Rails 2. WEEK 5 THRU 6- Upper Roller Rails and

Center Journal Bearings 3. WEEK 7 THRU 8 -

Hoist and Drag Drum

Barrel to Ends.

4. WEEK 5 THRU 10- Rotating Frame 5·. WEEK 9 THRU 12- Swing Cases, Hoist and

Drag Cases and Pedestals 6. WEEK 11 THRU 12- Walking Shoes 7. WEEK 13 THRU 14- Roller Circle Cage 8. WEEK 13 THRU 16 -

Boom

9. WEEK 15 THRU 16- Boom Point Area and

Rope Deflector Assembly 10. WEEK 17 THRU 18 -

Propel Gear Case and

D D D D

Systematically inspect structures thoroughly and retorque all major holding bolts and rods. This entails cleaning as needed for inspection.

D D

Repeat inspection schedule for Weeks 27 thru 52.

D D D D D D D D

D D D D

D D

Pedestals 11. WEEK 17 THRU 20 -

Tri-Structure

12. WEEK 19 THRU 22 - Tri-Structure Sheaves

and Fairlead Assembly

D D D D

14. WEEK 23 THRU 24 -

D D D D

15. WEEK 25 THRU 26- Propel Linkage and

D D

13. WEEK 21 THRU 22- Fairlead

House Roof, Arches, Supports, Propel Linkage and Exciter Set M-G Sets

(

14.

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE OPERATIONAL CHECK POINTS MONTHLY - EVERY 600 HOURS

MODEL

SIN

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

SHIFT

1

2

3

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

OPERATOR INSPECTOR

DESCRIPTION

STATUS

ACTION I REMARKS

YES NO

2. Walking Shoe Return Assembly

D D D D

3. Intermediate Boom Support Rope

D D

Verify gauge tension and adjust to correct specifications.

4. Perform Electrical Ground Circuit Check

D D

Electrician Megger check. Trip relays for grounding system.

1. Compressor Crank Case Oil

Change.

Check rope and spring condition. Clean and readjust accordingiiY to obtain correct shoe position.

MONTHLY - EVERY 600 HOURS

15.

EM029421-0 (en-us)

OUARTERLY - EVERY 1,800 HOURS

16.

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE OPERATIONAL CHECK POINTS QUARTERLY - EVERY 1,800 HOURS

MODEL SHIFT

S/N

1

2

3

OPERATOR INSPECTOR

DESCRIPTION

STATUS YES

ACTION I REMARKS

NO

1. All Enclosed Gear Cases

D D

Obtain oil sample from each case. Check for foreign material. Change as required.

2. Walking Eccentric and Thrust Washer

D D

Measure running and record.

clearance

3. Walking Arm and Connecting Link

D D

Measure running and record.

clearance

4. Main Propel Shaft

D D

Measure running and record.

clearance

5. Center Journal

D D

Measure running and record.

clearance

6. Fairlead Swivel Frame Posts and Thrust Washers

D D

Measure running and record.

clearance

7. Roller Circle Thrust Washers

D D

Measure running and record.

clearance

8. Hoist Rope Deflecting Sheaves

D D

Measure running and record.

clearance

9. Shoe Knuckle and Thrust Washer

D D

Measure running and record.

clearance

10. Boom Point Spherical Bushings

D D

Measure running and record.

clearance

11. Intermediate Hoist and Drag Shaft Pinion Retainer Bolts

D D

Check torque and retighten as required.

12. Isolator Switch in Tub

Check operation.

13. Brake Linings All Motions

D D D D

14. Check All Anti-Friction Bearing Operation

D D

Use stethoscope or vibration detection device to determine condition. Replace as required.

Measure lining thickness. Replace as required.

17.

EM029421-0 (en-us)

SEMI-ANNUAL - EVERY 3,800 HOURS

(

18.

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE OPERATIONAL CHECK POINTS SEMI-ANNUAL-EVERY 3,600 HOURS

SIN

MODEL

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

SHIFT

1

2

3

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

OPERATOR INSPECTOR

STATUS

DESCRIPTION

YES

ACTION I REMARKS

NO

1. Enclosed Gear Cases

D D

Open all cases and inspect condition of all gears, teeth and shafts.

2. Open Gear Systems

D D

Clean thoroughly - dye check root sections.

3. Gear Segments

D D

Clean thoroughly - dye check all welded joints.

4. Motor Couplings

D D

Inspect for lubrication.

5. Propel Coupling

D D

Inspect for fit and spline wear.

6. Hoist and Drag Drum Ends and Barrels

D D

Clean thoroughly to locate any cracks and repair as required.

7. Walking Arms and Eccentrics

D D

Clean thoroughly to locate any cracks - repair as required.

8. Sheaves

D D

Inspect all sheaves- identify candidates for replacement.

9. Hook Rail Flatness

D D D D

Clean -

D D

Inspect fit of bearing housing pins to pedestals at each shaft.

10. Boom Support Rope 11. Hoist Drum Shaft, Intermediate Hoist Drum Shaft, Drag Drum Shaft, Intermediate Drag Drum Shaft and Main Propel Drive Pinion Shaft

Electrical Maintenance

& Danger -

measure and record.

Remove socket dampener and lubricate.

Disconnect Power

12. High Voltage Collector Ring Assembly

D D

Check general condition by qualified and licensed electrician.

13. Motor Generator Set

D D

Megger check wiring/insulation integrity by qualified and licensed electrician.

14. Synchronous Motors

D D

Megger check ground continuity by qualified and licensed electrician.

19.

EM029421-0 (en-us)

ANNUAL - EVERY 7,200 HOURS

(

(

20.

.

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE OPERATIONAL CHECK POINTS ANNUAL - EVERY 7,200 HOURS

MODEL

stN

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

SHIFT

1

2

3

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

OPERATOR INSPECTOR

DESCRIPTION

1. Air Valves (Not Identified on Illustration) 2. Air Tanks 3. Autolube Control Valves 4. Circle Rollers

STATUS YES

NO

D D D D

D D D D

5. Bearings and Shafting (Not Identified on Illustration)

D D

6. Main Swing Shaft

D D D D D D D D D D D

7. Main Swing Shaft 8. Hoist, Drag, Propel Motor Extension Shafts 9. Hoist, Drag, Propel Intermediate Shafts 10. Hoist and Drag Drum Shafts 11. Second Intermediate Propel Shaft 12. Main Propel Drive Pinion Shaft 13. Boom Point Shaft Sheaves 14. Center Journal .o. Oil Seals and Lubricating Oils (Not Identified on Illustration 16. Non-Destructive Test on Backleg Eyes and Pins

D D D D D D D D D D D

ACTION I REMARKS

Remove and clean.

Drain, inspect for cracks and repair as necessary.

Clean and re-condition.

Remove every tenth roller and clean. Measure and record inside/outside diameters. Inspect bushing, thrust washer and lubrication channels. Replace worn or fatigued parts as required.

Remove gear case covers and cup retainers. Inspect for wear.

Record and photograph for future reference.

Inspect gear top at five (5) locations.

Inspect above pinion at five (5) locations.

Inspect for wear at ten (10) locations.

Inspect for wear at six (6) locations.

Inspect for wear at two (2) locations.

Inspect for wear at two (2) locations.

Inspect for wear at two (2) locations.

Inspect for wear at two (2) locations.

Inspect for wear at one (1) location.

Change oil seals and oil in all enclosed gear cases.

Perform by qualified metallurgist and record.

(Continued next page)

21.

EM029421-0 (en-us)

BIENNIAL - EVERY 15,000 HOURS

EM029421-0 (en-us)

7,200 HOURS CONTINUED (SEE ILLUSTRATIONS PREVIOUS PAGE) 17. Non-Destructive Test on Tri-Structure Top Eyes and Pins

D D

Perform by qualified metallurgist and record.

18. Non-Destructive Test on Boom Support Rope Sockets, Eyes and Pins

D D

Perform by qualified metallurgist and record.

19. Non-Destructive Tests on Hoist and Drag Drum End Stub Shafts

D D

Perform by qualified metallurgist and record.

20. Non-Destructive Test on Main Rotating Shafts

D D

Perform by qualified metallurgist and record.

21. Backleg Safety Cable

D D

Test to specified tension. (See erection documentation.)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE OPERATIONAL CHECK POINTS BIENNIAL - EVERY 15,000 HOURS

MODEL

SIN

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

SHIFT

1

2

3

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

OPERATOR INSPECTOR

DESCRIPTION

STATUS YES

1. T-Joint Weld in Tub 2. T-Joint Weld in Upper Frame 3. Hook Shoe Path on Tub

ACTION I REMARKS

NO

D D D D D D

Inspect and repair cracks.

Inspect and repair cracks.

Inspect with square trueness, straighten/flatten with shims.

8. Boom

D D D D D

9. Non-Destructive Test Boom Chords

D D

Perform by qualified metallurgist and record.

J. Non-Destructive Test Boom Point Structure

D D

Perform by qualified metallurgist and record.

D D

Disassemble and inspect for loose or worn parts.

4. Propel Linkage Area Structures 5. Walking Arm Structures 6. Stabilizer Arm Structures 7. Walking Cams

11. Boom Point Shaft Assembly

D D D D D

Check for fatigue.

Check for fatigue.

Check for fatigue.

Check for fatigue.

Lower boom to cribbing and inspect.

23.

EM029421-0 (en-us)

MACHINE IDENTIFICATION

25,000 HOUR MAINTENANCE INSPECTION SCHEDULE

MODEL SHIFT

SCHEDULED COMPONENT REPLACEMENT

S/N 1

2

i

3

\

OPERATOR INSPECTOR

DESCRIPTION

STATUS YES

NO

D D D D

D D D D

ACTION I REMARKS

6,000-10,000 HOURS

1. Intermediate Boom Support Ropes 2. Autolube System Air Pumps 3. Oil Seals in Enclosed Gear Cases 4. Oil Seals in M-G Set Bearings

Replace in sets.

Replace.

Flush and clean. Add new oil.

Replace.

14,000-20,000 HOURS

1. Hoist Motor Extension Shaft Pinions 2. Air Compressors 3. Fairlead Swivel Frame Bushings

D D D D D D

Replace.

Overhaul and/or replace.

Replace.

25,000 HOURS

1. Drag Motor Extension Shaft Pinion 2. Swing Motor Extension Shaft Pinion 3. Propel Motor Extension Shaft Pinion 4. Rope Sheave Anti-Friction Bearings 5. Hoist and Drag Drum Anti-Friction Bearings 6. D.C. Motor Anti-Friction Bearings 7. Exciter Set Anti-Friction Bearings

8. Motor-Generators Anti-Friction Bearing 9. Boom Support Ropes

10. Autolube System Control Valves 11. Autolube Injectors 12. Brake Air Magnet Valves

D D D D D D D D D D D D

D D D D D D D D D D D D

Replace.

Replace.

Replace.

Replace all bearings.

Replace.

Replace.

Replace.

Replace.

Replace in sets.

Overhaul and/or replace.

Replace.

Replace.

r

~.('