CAT BUCYRUS MARION 204-M-HR Super Front MAINTENANCE AND OPERATION MANUAL – PDF DOWNLOAD

Description

CAT BUCYRUS MARION 204-M-HR Super Front MAINTENANCE AND OPERATION MANUAL – PDF DOWNLOAD

FILE DETAILS:

CAT BUCYRUS MARION 204-M-HR Super Front MAINTENANCE AND OPERATION MANUAL – PDF DOWNLOAD

Language : English
Pages : 530
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT BUCYRUS MARION 204-M-HR Super Front MAINTENANCE AND OPERATION MANUAL – PDF DOWNLOAD

INTRODUCTION

• The information contained in this manual provides guidance to all persons who care about the operation and maintenance of this machine. Needed data for operation, lubrication, adjustments and other tasks supplied in the various sections permits accurate operation and service.
• This information allows for quality maintenance when followed exactly. This Manual is NOT a Parts Book. Do not use it to order parts. You have been supplied with a separate, detailed Parts Book. Please read carefully the instructions in the front of it. All parts are listed by group number with items and part numbers for this SPECIFIC machine.
• Please order the correct parts in exact quantity. Parts ordered by mistake and returned are subject to a Company rehandling charge. RIGHT and LEFT HAND PARTS on the upper frame correspond to the operator’s hands at the controls as he faces the dipper.
• Please state the correct machine SERIAL NUMBER in any conversation or correspondence. Records of each machine are filed by serial number. Given this number, the specific design and original equipment check is accurate and quick. ADDED INFORMATION, when required, not found in this Manual or the Parts Book may be obtained from your Local Service Representative.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT BUCYRUS MARION 204-M-HR Super Front MAINTENANCE AND OPERATION MANUAL – PDF DOWNLOAD

Engineering Data (Red) , Section 1
Lubrication (Green) , Section 2
Compressed Air Systems (Yellow) Section 3
Mechanical Adjustments (Orange) , ‘ Section 4
Electrical Maintenance (Blue) , ” Section 5
Hydraulics (Copper) , , ” Section 6
Operation (Gold) Section 7
Special Per Sales Order Requirements (Maroon) Section 8
Schematics – Colored (Light Blue)
Straight Bronze Sleeve Bushings
Flange Bushing 1
Bushing Life 1
Bushing Replacement
Running Clearance for Bronze Bushings 2
Installation of Oil and Grease Seals 4
Split Seals 4
Two Seals Installed 5
Gear Case Seal 5
Installation of Vee Type Grease Seals 6
Surface Preparation 6
Adhesive Removal 6
Adhesive Application 7
Cured Splines Disassemble 7
Involute Spl ine Assembl ies Permanent Fit with Adhesive 7
Install ing Anti-F riction Bearings on Shaft 7
Installation of Shrink Fit Pinions 8
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(Sec 1 – Engineering Data cont ) Page
Pinion Removal 9
Shrink Fit Mounting Data 10
Cap Screw (Bolt) Class 11
Turn-of-Nut Method 11
Torque Method ‘ 11
Engineering Standard 1101-2 13
Gear Inspection Procedures:
Method of Checking Rim Face Runout of Gear 15
Checking Radial Runout of Gear 15
Allowable Radial Runout 15
Required Backlash 16
Setting of Pinion for Backlash and Tooth Contact ” 16
Place Pinion Assembly in Position 17
Checking Tooth Contact and Backlash 17
Alternate Method of Checking Tooth Contact and Backlash 18
Final Check for Uniform Contact Pattern 18
Typical Contact Patterns 19
Inspection 19
Gear Maintenance Procedure:
Operation of Gears 20
Handling 20
Pinion Replacement 20
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(Sec 1 – Engineering Data cont ) Page
Care of Wire Rope:
Guide to Long Life Thru Proper Handling and Care 21
Selection of Rope ” 21
Handling and Installation of Strand Pendants ” 27
Common Precautions • 27
Coils • , • 28
Reels 28
The Right Way to Recoil , , 30
The Wrong Way to Uncoil Wire Rope , 30
Kinks , , 30
Welding Information:
Recommendations for Casting Repairs , 31
Proper Preparation for Welding 32
Preheat 33
Increase , 33
Maintain • 33
Postheat 33
The Order of Welding 33
Peening 33
Reinforcing Requires Extreme Caution 34
Postheat Treatment 34
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(Sec 1 – Engineering Data cont ) Page
Material Identification, Marion Material Symbols and Major
Component Parts 34
Material Information:
Rail Steel 35
Austenitic Manganese Steel ” 35
Friction Housing 35
Welding Instructions 35
Descriptions and Brinells 38
Electrodes 38
Preheats and Postheats 38
O-Ring Guide:
Squeeze , 41
Recovery 41
Metal to Metal 41
Most O-R ing Problems 42
Poor Installation 42
Preparation 44
Installation 45
Backup Rings 45
Basic Things to Remember 47
Modes of Failure 48
Decimal Equivalents 48
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(Sec 1 – Engineering Data cont ) Page
FalkCouplings 49
Lubrication of Coupling During Assembly 52
Keyless Couplings:
Assembly of Keyless Couplings 53
Removal of Keyless Coupling 53
Pressure Equipment 54
Finishing and Recommended Fits 55
Checking Coupling Alignment 55
The Solidly Coupled Sets Procedure 55
Coupling Alignment (Representative Readings) 57
204

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