PDF Maintenance & Operation Manual Cat Bucyrus Marion 195-M Crawler Dragline - 1 MB
This comprehensive manual covers the maintenance and operation of the massive Cat Bucyrus Marion 195-M crawler-mounted dragline.
It provides detailed procedures for operating this specialized mining equipment safely and efficiently.
The maintenance sections are crucial for scheduling service and performing repairs to ensure the machine's longevity and reliability in harsh mining environments.
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BI006284
Ā© Bucyrus
All Rights Reserved
BUCYRUS R
Technical Manual
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BI006284
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SAFETY PRECAUTIONS
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This safety alert symbol is used here and throughout this manual to call your
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attention to instructions concerning your personal safety. Carefully read and
follow these instructions and observe all safety and danger, warning and caution
graphics mounted on various areas of the machine.
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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
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and operational procedures contact your regional Marion service representative or the
factory. I
The following defines distinctions between safety instructions. In all these definitions the
safety alert signal is used. I
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DANGER: D _ extr8mo intrinsic hazard which exists and could result in
high probability of death or irreparable injury if proper precautions
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are ignored.
WARN ING: Denotes a hazard exists which can result in injury or death if proper
precautions are ignored. I
.\ \ , CAUTION: Denotes a reminder of safety practices or directs attention to unsafe I
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practices which could result in personal injury if proper precautions
are ignored.
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An example of a safety alert symbol and special safety instructions is shown below.
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A, DANGER: Inherent danger exists in the operation of any high voltage electrical
equipment. A safe grounding system includes ground conductors in
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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.
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Operating, maintaining or servicing this machine can be dangerous unless performed proper-
ly. 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.
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Factory service representatives and specialists are available to provide additional informa-
tion or technical assistance. I
1-2
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VISUAL INSPECTION of the machine should be performed by the operator at the begin-
ning of each shift. A potential problem may be prevented if discovered early. The follow-
ing check list should help with the inspection. I
GENERAL CHECK LIST for aH areas of the machine:
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Is power source properly grounded
Are guards, cover plates and safety devices secured in place
All wiring harness secured in proper manner
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Are electrical terminals tight
All loose pieces stored in proper place or removed from machine
Check ALL hardware for tightness, missing bolts, nuts, pins, etc.
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Proper lube supply to all bearing and lube points
All lube (grease) spills wiped up
The machine thoroughly CLEAN
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LOWER FRAME CHECK LIST - Note the following items:
Trail cable condition
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Air and lube tines connections
Oil level in gear cases I
No obstructions in roller path or rotating gear
Crawler balt(s) adjustment and condition
Crawlers and lower frame for cracks and/or broken welds
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FRONT END EQUIPMENT - Check the following items:
Bucket for worn, broken or missing teeth, loose or missing pins, weld cracks
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Note condition of drag and dump chains
Boom, mast and gantry for cracks, bent pipes and/or plates
Condition of fairlead components
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Condition of boom and mast support ropes
Condition of hoist and drag ropes
Lubrication lines connections
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MACHINERY HOUSE - Check the following:
Automatic Lube systems has adequate lube supply
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Gear cases lube levels
Air compressor lube level and drive belts I
All gearing for cracks, wear, proper lube
Air and lube lines connections
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NOTE: If any problems are found after going thru the above check lists, notify mainte-
nance at ONCE, so correction can be made.
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2-10
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NOTE: Unusually dusty or dirty atmosphere, high humidity and extreme temperatures af-
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ter the effective life of a lubricant. Therefore, it shall be the responsibility of the owner/op-
erator to determine the most effective lubricant interval according to existing environmental I
conditions for all components, bearings (plain and anti-friction), gears, gear cases, etc.
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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
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the most likely point of boom point support wire rope failure. To avoid this condition and
increase useful life expectancy of the wire rope support rope apply wire rope lube to the
socket area using the hand spray.
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CHECK LIST for initial lubrication start up and any inspection following:
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Clean up spilled petroleum products immediately. I
Remove promptly any petroleum product that gets on your skin.
Don't use gasoline, naphtha, turpentine, or similar solvents to remove oil or
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grease from your skin.
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Don't use dirty wipe cloths.
Avoid breathing oil mist or solvent vapors. I
Don't wear oil-soaked garments. I
Remove grease accumulation around bearing and gears.
All grease piping connected and filled.
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Proper lube supply to all bearing and lube points. I
NOTE: All anti-friction bearings and bushings have correct initial lube fill
per manufacturer's recommendations. I
Proper oil level in all gear cases.
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Open and semi-enclosed gear teeth coated with lube.
Automatic lubrication system with adequate lube supply. I
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3-2
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NO. OF LUB. METHOD &
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NAME OF PART TYPE POINTS LOCATION SYM. FREQUENCY
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LUBRICATION OF UPPER FRAME (cant.)
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Hoist Motor Anti- 2 Bearing Retainer MPG Man., 500 hrs.
Ext. Shaft Friction
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Hoist Motor Inside Hub MPG Check, 30 days
Coupling 3-6 mos. lube
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Hoist Brake 11 MPG Man., weekly
Hoist Motor Anti- Motor End EMG Man., see elec-
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Friction Casting trical manual
Drag Drum Gear 4 Drip on Teeth OGL Auto, 12 min.
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Int. Drag Gear 5 Drip on Teeth OGL Auto, 12 min. I
Drag Drum
Support Bearing
Anti-
Friction
2 Top of Boss MPG Man., 500 hrs.
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Int. Drag Shaft Anti-
Friction
2 Bearing Housing MPG Man., SOD hrs.
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Drag Motor
Ext. Shaft
Anti-
Friction
2 Bearing Retainer MPG Man., 500 hrs.
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Drag Motor
Coupling
Inside Hub MPG Check, 30 days
3-6 mos. lube
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Drag Motor Anti-
Friction
Motor End
Casting
EMG Man., see elec-
trical manual
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Drag Brake No lubrication required I
Swing Gear Case 2 F ill at Breather
101 gal. each
GL Check dai Iy at
dip stick I
Swing Motor Motor End
Casting
EMG Man., see elec-
trical manual I
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3-12
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Section 4 - Mechanical Adjustments (cont.) Page
Steering Clutch Assembly/Adjustment (cont.):
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Diagram C 4-22
Diagram D 4-23 I
Propel Brake
Air Requirements
4-24
4-24
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Operating Temperatures 4-24 I
Brake Removal and Installation:
Removal of Brake 4-26
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Installation of Brake 4-27
Brake Alignment
Air Piping
4-28
4-29
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Brake Maintenance:
Points to Check When Inspecting the Brake 4-29
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Brake Adjustment 4-31
Friction Lining Replacement
Piston Replacement
4-32
4-32
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Roller Circle and Main Swing Gear:
Roller Circle 4-33
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Main Swing Gear 4-35
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Roller Replacement 4-35
Center Journal 4-35 I
Center Journal Nut ......ā¢................................. 4-35
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Roto Seal Assembly 4-35
Removal of the Center Journal 4-39
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To Install a New Journal 4-39 I
Hoist Machinery:
Hoist Drum Removal
Hoist Gear Removal
4-39
4-42
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Remove lube guard and disconnect lube piping to roller. Remove roller shaft retainer bott
from back side of shaft. Support roller on jack and cribbing or use a handling fixture similar
to sketch. Each roller weighs about 1,000 pounds (with bushing and thrust washers).
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HANDLING FIXTURE
..." Pull the 220 pound shaft from out-
side of crawler side frame. Care-
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fully lower roller. As roller clears
side frame, clamp thrust washers
to prevent loss of dowel pins and
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springs.
Reverse operation to install new
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roller. Be sure to fill bushing with
grease before replacing lube guard. I
Reconnect crawler belt and adjust
tension.
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NOTES:
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4-6
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Remove the bearing retainer from the right end of the shaft. Pull the shaft (1,290 pounds)
from the right side of the case. Move the intermediate gear toward the front of the case and
block. The main propel shaft and first intermediate shaft must be removed before the inter-
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mediate gear can be removed from the case.
REMOVE THE MAIN PROPEL SHAFT by first removing the bearing retainer (216 pounds),
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oil seal and shims from the right end of the shaft and the oil seal from the left hand bearing
retainer. I
Block or suspend the main propel gear (4,800 pounds). Pull the shaft (2,940 pounds) from
right side of the gear case. I
NOTE: As the shaft is being pulled, the roller bearing and spacer at left of propel gear must
be held in place until the shaft is removed. I
Lift the main propel gear out of the case.
roller bearing.
Remove the left hand propel gear spacer and
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REMOVE FIRST INTERMEDIATE i
intermediate gear (1,204 pounds).
PROPEL SHAFT next. Block up or suspend the first
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Remove the left hand retainer (55 pounds) and shims. Remove the bearing retainer from
the left end of the quill shaft. Suspend the quill shaft (633 pounds). Remove the right
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hand bearing carrier (250 pounds). Remove the quill shaft from right side of case. Lift the
first intermediate gear from the case. I
NOTE~ When pulling quill shaft the left bearing must be held in place until the shaft is
removed. I
The second intermediate gear can now be removed from the case.
Clean the gear case thoroughly after all parts are removed. Clean and check all parts for
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damage or excessive wear. Replace defective parts.
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ASSEMBLY OF PROPEL COMPONENTS: I
Lower the second intermediate gear, with the hub counterbore toward the right side, into
the gear case. Block gear to the front (not in position) of case.
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FIRST INTERMEDIATE PROPEL SHAFT - Install the gear spacer on long end of the
quill shaft. Heat the right hand bearing and install on quill shaft.
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4-16
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BRAKE REMOVAL AND INSTALLATION-
CAUTION: Read these instructions thor-
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oughly and review until you fully under-
stand the brake removal and installation
sequence before proceeding with the work
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described in this section. Failure to follow
these instructions will result in unreason-
able exposure to hazardous conditions or
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personal injury.
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A. REMOVAL OF BRAKE
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This brake is supported and reacted by a single re-
action pin. The brake is held in position on the pin
by a washer and two locknuts. For brake removal, I
proceed as follows:
1. Set and block the machine in a safe position to
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prevent hazards when the brake is released. Dis-
connect all electrical power.
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2. With air released from cylinder (34), disconnect
the flexible air connection into the cylinder. I
3. Detach spring shields (39) by removing cap
screws (40) and lockwashers (41). I
4. Back off two stop nuts (18) from one end of
spring rod (15) until the outboard nut is flush
with the end of the spring rod (15). The inboard
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nut must be touching the outboard nut. Then, I ā¢
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from the other end of the spring rod (15) re-
move the outboard stop nut (18) and back off
the inboard stop nut until it is flush with the
end of the spring rod. I
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A WARNING: Failure to follow this procedure can cause the spring/rod assembly
~ to become a projectile capable of causing damage and/or personal
injury.
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4-26
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LOCK PLATE
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~o~~ AO.>JST NUTTO MA'.TA'N
1/4 INCH CLEARANCE BETWEEN
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I ROLLER PATH (TOP RAIL) AND
I ROLLERS AT REAR OF MACHINE
WITH MACHINE UNDER LOAD
- REFER TO DETAILED
ADJUSTMENT PROCEDURE IN
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THIS SeCTION
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LOWER FRAME,
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CENTER JOURNAL
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4-36
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REASSEMBLE INTERMEDIATE HOIST SHAFT ASSEMBLY. First, lightly lube the shaft
and slide the pinion on until it seats.
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Slide the inner bearing retainer and spacer onto the shaft, against the pinion.
Heat the bearing to 200 degrees F.
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Install the bearing on the shaft and secure with the retainer plate and cap screws. Wire lock
cap screws.
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Install the housing and bearing cover. I
Support the intermediate gear and slide it onto the shaft.
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Install the inner bearing retainer and spacer on left end of shaft.
Heat the bearing to 200 degrees F.
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Install the bearing on the shaft and secure with the retainer plate and cap screws~ Wire lock
the cap screws.
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