Cat Bucyrus M-4 & M-5 Blast Hole Drill Maintenance & Operation Manual BI005701 - PDF DOWNLOAD

Page 1

Technical Manual

© Bucyrus All Rights Reserved
R BUCYRUS BI005701 0

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M-4 & M-5

BLAST HOLE DRILL MAINTENANCE

AND OPERATION

MANUAL 2001 R
MARION POWER SHOVEL DIVISION • DRESSER INDUSTRIES, INC. Printed jp LJ SA BI005701

I!! IMPORTANT NOTE I!!

THIS MANUAL HAS BEEN REVISED TO REFLECT THE FOLLOWING CHANGES

SPECIFIC TO THE M-5 DRILL SIN 23075:

- SECTION 3, P. 13 - GEARBOX GUIDE SHOES

- SECTION 3, P. 17 - STEM RACK ASSEMBLY

- SECTION 3, P. 29 - DRILL AIR COMPRESSOR LUBRICATOR

- SECTION 4, PP. 56-74 - MAIN PUMP CONTROLLERS

BI005701

STANDARD WARRANTY

All goods are sold and delivered subject to standard manufacturing and other variations and practices customary in the trade. Seller warrants goods manufactured by Seller to be free from defects in material and workmanship under normal use and service for a period of six (6) months from the date of del ivery, provided that the goods have, since the date of delivery, been properlv used, maintained and stored, and no repairs or alterations thereon have been carried out without Seller's consent in writing. Liability of Seller for goods found to be defective or not in accordance with agreed specifications or for other breach of contract, negligence, strict liability or otherwise shall be limited to replacement of goods F .O.B. Seller's plant or return of goods and refund of the purchase price therefor as the Seller shall elect. Goods which have not been manufactured bV Seller shall be subject on Iy to such warranty as may be made by the manufacturer thereof. TH E GOODS ARE SUBJECT TO NO OTHER WARRANTIES, EXPRESS OR IMPLIED. SELLER DISCLAIMS AND BUYER WAIVES ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS OTHER THAN THE EXPRESSED SIX MONTHS WARRANTY SET FORTH ABOVE.

Marion Power Shovel Division shall not be held responsible or liable in any event for special or consequential damages, arising from anv cause whatsoever, and Buyer agrees to indemnify and save Marion Power Shovel Division harmless therefrom.

Marion Power Shovel Division reserves the right to improve or change '" the design of its products and specifications thereof and the Marion Power Shovel Division shall incur no liability thereby or any obligations to install such improvements on products previously sold. ["""'0";'

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BI005701

DUE TO THE DANGERS INHERENT IN THE OPERA.TION OF ANY HIGH VOLTAGE ELECTRICAL EOUIPMENT, A SAFE GROUNDING SYSTEM

SHOULD INCLUDE GROUND CONDUCTORS THE CABLE, A. NEUTRAL GROUNDING RESISTOR AND RELATED RElJ\YS AND SWITCHGEAR. A GROUND CONTlr'JUiTY CHECK ,A,LSa RECOMMENDED.

In the event you doubt, for any REASON, your ability to safely perform anv of the enclosed maintenance and operational procedures as they refer to your machine; please contact your Local Service Rei)resentative.

READ AND OBSERVE ALL warning signs, they're placed for your health and safety.

This manual has been prepared for the standard production machine. AnV deviation due to advanced engineerinq design, optional equipment or the particular requirements ot this machine may not be covered.

Additional information that IS required will be furnished as soon as such information is available.

-BI005701

TABLE OF CONTENTS

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Introduction Engineering Data Section 1 Lubrication Section 2 Machinery Section 3 Hydraulic Systems Section 4 Compressed Air System and Components Section 5 Operation Section 6 Electrical Section 7 Maintenance Check List Section 8 BI005701

-WARNING-

DUE TO THE DANGERS INHERENT IN THE OPERATION OF ANY HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM SHOULD BE USED. SUCH 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

In the event you doubt, for REASON, yoar abilitY"to safely perform any of the enclosed maintenance and operational procedures as they refer to your machine, please contact Marion Power Shovel Company, Inc.

-WARNING-

PERSONNEL MUST NOT BE PERMITTED UNDER THE MACHINE NEAR THE DRILL MAIN AIR RELIEF VALVE(S). AIR DISCHARGE THROUGH THE RELIEF VALVES IS DANGEROUS AND SERIOUS INJURY MAY RESULT.

READ AND OBSERVE ALL WARNING SIGNS. THEY ARE PLACED FOR YOUR HEALTH AND SAFETY. KNOW THE LOCATION OF THE FIRE EXTINGUISHERS.

This manual has been prepared for the standard production machine. Any deviation due to advanced engineering design, optional equipment or the particular requirements of this machine may not be covered.

BI005701
INTRODUCTION INDEX Page Standard Warranty Safety Suggestions .......................................... , . 2 Caution is the By-Word 2 Liquid Capacities of Drill (U.S. Gallons) 5 l'i/1-4/M-5 BI005701

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. All enclosed specifications agree with the Marion Power Shovel Engineering Department. 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 L.EFT HAND PAHTS on the upper frame correspond to the operator's hands at the controls as he faces the bucket. 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 Mar;on Power Shove! Company. I nco at Marion, Ohio 43302.

SERVICE and LABOR CHARGES are NOT accepted unless previously authorized by the Company in writing.

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.NTRODUCTION
M-4/M-5 BI005701

SAFETY SUGGESTIONS

The operator controls the machine and its usefulness. The crew alone thinks for it. Safety, constantly in mind, prevents accidents. Develop good habits. Everyone has bad habits, bu.t try to erase them quickly. Cleanliness and safety go together. A clean machine is easier to operate, inspect and maintain.

READ and OBSERVE ALL warning signs, they're placed for your health and safety.

KNOW the location of fire extinguisher.

DO NOT START machine without a FULL tank of air pressure.

DO NOT LEAVE the controls without pushing the STOP BUTTON marked "EXCITATION", turning BOTH brake switches to "SET" and automatic drill control lever to the center detent position.

DO NOT SERVICE or lube moving parts.

PLEASE READ carefully this Manual and Parts Book.

PLEASE LUBE regularly.

PLEASE CREATE A SYSTEMATIC maintenance procedure and follow it.

PLEASE WATCH clearance when lowering mast.

PLEASE OPERATE machine on as near level ground as possible.

PLEASE KEEP safe operating procedures in mind at ALL times.

CAUTION IS THE BY-WORD. Develop a feel for the machine. Try to sense failure before it arrives. Take that extra second to look again at something that seems out of place. paint chip or bubble may be an early warning. A slight hiss may indicate a growing air leak. It's much easier to tighten a packing nut than shutdown for packing repair.

PROPERLY GROUND the power source.

WATCH AI R system performance.

CHECK pull down chains for early signs of wear or failure that may cause permanent damage.

CHECK LIMiT switches for proper operation.

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M-4/M-5 Page 2 BI005701

CH ECK OVE R LOAD and thermal breakers.

MAl NT AI N correct supply of lubricant.

MAINTAIN CLEAR

LOOK FOR loose bolts and locking devices.

KEEP FLOORS CLEAN and free of oil and grease.

WI PE AWAY excess grease and oil around bearings and gears.

KEEP hands, feet and clothing away from moving parts.

PROMPTL Y REPLACE all guards, inspection doors, access covers and other safety features after inspection or repair.

NEVER attempt electrical repair, unless qualified.

HIGH VOLTAGE power lines reguire using EXTREME CAUTION.

Open pit mining equipment undergoes tremendous shock and stress. Marion's design considers these loads. This machine, built with an ample reserve of power and strength, will meet the demands of its task. Marion's engineers cannot foresee the conditions imposed by abuse, neglect and mismanagement. These factors damage any piece of equipment more than years of continuous operation and normal wear. Care, sound judgement and reason govern the economic need in the operation of power equipment.

Downtime exists, but an ongoing program of inspection and evaluation minimizes it. Awareness of unusual conditions generally warns personnel before breakdown occurs. Normal wear of machinery parts escapes exact definition. Parts do not suddenly expire. Wear takes place at varying degrees over time. Constant checking indicates a wear pattern. An alert maintenance crew checks A.LL structural members for evidencf! of stressed, broken or loose items. Minor cracks occur in steel structurus. it's true of ALL machines. This is I\JOT SERIOUS when weld repaired while SMALL. Coid causes faster expansion and brittleness than warm weather. Ear!v detection and quick repair prevents failure. A stretch, bend or defect often shows up in condition of surfdce paint. A collection of dust along a linE may indicate a crack in the meta!. Look closely at areas around openings where angles are cut out. Also check gusset connections ana points where thin and h,=,ClVV metals ioin. The good crew watches for bolts, cap screvvs, lock washers anc1 other locking devices. Rod bolts are important too. Signs ot scuffed paint, worn or briJtlt spots next to any part indicate movement and becomes second nature to most personnel, Retighten ALL bolts shortly after initial start up. Grease and oil stqins often indicate problems. Perhaps just pour housekeep i ng. but at least someth ing 15

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Replacement and maintenance schedules may conform to planned shutdowns. Lack of proper lube, poor adjustments and abuse cause and speed up wear. These facts show up as the MAl N reasons for breakdown. If any part shows wear or distortion beyond expected normal wear, order replacement and quickly install. The cost of parts is nothing when compared to breakdown cost and loss of man hours and production.

production machines operating 24 hours, 7 days every week deserve an 8 hour inspection and cleaning every 10 days. Cleaning before inspection eliminates dirt and dust falling into machinery parts when inspection plates and covers are removed.

A solvent makes removal of the accumulation of oil and grease in the machinery house easier.

Run the rotary gearbox and propel gearbox in each direction. Sound here may indicCilte damaged teeth on the gears. Check gearbox for oil leakage and visually inspect all seals. Check oil level with dipstick.

Check rotary gearbox alignment in hoist and pull down and examine the guide rollers for wear. Check for side to side cocking of gearbox in pull down. This could indicate an unequal number of links in the two pull down chains. Examine chains for excessive wear or failure.

Examine craV\ler belt for worn pins and broken keeper bolts. Check for cracked or broken shoes. Examine crawler drive sprocket for cracking or excessive wear. Check propel chain for excessi"ve wear or failure. Examine hydraulic hoses for early signs of failure.

Check oil level in hydraulic tank, check dirty filter indicators at ful! system flow. Check gauges on tank for low charge pressure and high suction line vacuum.

Check and clean if necessary the inlet filter for the main air compressor. Check for proper operation of the three butterfly valves. Examine the main air piping for leaks. Check operation of the force feed rubricator. Check V belt tension and tighten or replace belts if needed,

Examine and readjust, if needed, the hoist pull down brakes. L'j'ik at the condition of brake lining. Examine condition of propel brakes. Check auto-lube :;vstem for loose or broken fittings or injectors

Secure ALL Duards and safety features in place. DISCONNECT POWEri SOURCE with machine shut down so electrical crew may adequately clean and inspect motor generators and electrical cabinets. r\lOTE any discolorco electrical p;::rts is a siqn of overheating. In humid areas, look for funijus and Dry compressed ai, <'t LOW pressure works well for dust removal. Clean corrosion from parts, joints and conrlcctions. Retighten, where needed, any loose connections and terminals. Use of proper tool here eliminates brokerl

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M-4/M-5 Page 4 BI005701

terminpls and terminal blocks. Repla<;e missing or damaged tags and labels. Bundle loose wiring. Fasten ALL components and wiring in cabinet$. Check the cable armor tight in the fixture. Look closely where wires and cables pass thru openings and grommets. Insulation damage generally occurs here. Replace grommets if needed. Arcing of motors and generators causes discolored commutators. Look at brushes and brush holder condition. Correct brush spring tension where needed. Remember to replace ALL plugs, covers and inspection plates.

Passing equipment condition reports along the line is important also. Wear patterns show up at varying degrees in time. Recording and checking these reports at a future date allows comparison and planned shutdowns. Planned repairs, part orders and crews for a scheduled shutdown eliminates idle downtime.

A good troubleshooter attack plan includes:

Adequate preparation including:

Understanding the system and component function

Schematics and test data at hand

Quality test equipment designed for the job

Preliminary investigation to determine effect of fault

Estimation of probable cause

Test to determine faulty component

Correction of failljre

Preventative maintenance

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unulD CAPACITIES Of DRILL (U.S. GALLONS)
Auxiliary
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7 COtTioressor
Page 5 42 72 98 90 100 70 165 2 25 M-4/M-5 BI005701
1. Main HvdralJiic Tank
Hvdraullc Tank
Prouel
3. Drill Head Gearbox.
4. Drill Air Coolinq (Vi-5l ._ Drill Air Coclinq (M-4l
5. Hydraulic
Systern 6. Hydraulic Pump Tr'Hlsmi5sion, quar-ts
Lubricator, pints

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL

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