CAT Bucyrus M-4 & M-5 BLAST HOLE DRILL MAINTENANCE AND OPERATION MANUAL 2001 – PDF DOWNLOAD

Technical Manual

• 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.

M-4 & M-5

BLAST HOLE DRILL MAINTENANCE AND OPERATION

STANDARD WARRANTY

oods are sold and delivered subject to standard manufacturing and oth r variations and practices customary in the trade. Seller warrants goo s manufactured by Seller to be free from defects in material and wor manship under normal use and service for a period of six (6) mo ths from the date of del ivery, provided that the goods have, si nce the ate of delivery, been properly used, maintained and stored, and no rep irs 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 con ract, negligence, strict liability or otherwise shall be limited to replac ment of goods F.O.B. Seller's plant or return of goods and refund of te purchase price therefor as the Seller shall elect. Goods which hav not been manufactured by Seller shall be subject only to such war anty as may be made by the manufacturer thereof. TH E GOODS AR SUBJECT TO NO OTHER WARRANTIES, EXPRESS OR IMPLI D. SELLER DISCLAIMS AND BUYER WAIVES ANY IMPLIED WA RANTY OF MERCHANTABILITY OR FITNESS OTHER THAN TH EXPRESSED SIX MONTHS WARRANTY SET FORTH ABOVE.

n Power Shovel Division shall not be held responsible or liable in any vent for special or consequential damages, arising from any cause wha soever, and Buyer agrees to indemnify and save Marion Power Sho el Division harmless therefrom.

Mari n Power Shovel Division reserves the right to improve or change the esign of its products and specifications thereof and the Marion Pow r Shovel Division shall incur no liability thereby or any obligations to in tall such improvements on products previously sold.

IMA"'O"pMa

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.

In the event you doubt, for any REASON, your ability to safely perform any of the enclosed maintenance and operational procedures as they refer to your mach ine; please contact your Local Service Representative.

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

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.

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

TABLE OF CONTENTS

I ntr duction

Eng neering Data (Red)

Lub ication (Green, Mac inery (Orange) .

raulic Svstems (Copper)

Co pressed Air System al1d Components (Vellow)

Ope ation (Gold)

Ele trical (Blue)

Mai tenance Check List (Maroon I.

7

-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 REASbN; 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 DRI LL MAIN AI R RE LIEF VALVE(S). AI R 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.

INTRODUCTION

The inform ion contained in this manual provides guidance to all persons who care about the operatio and maintenance of this machine. Needed data for operation, lubrication, adjustments ad other tasks supplied in the various sections permits accurate operation and service. All enclosed specifications agree with the Marion Power Shovel Engineering Department. This nformation 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, etailed Parts Book. Please read carefully the instructions in the front of it. All parts are lis ed by group number with items and part numbers for this SPECI FIC 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 corre pond to the operator's hands at the controls as he faces the bucket. Please state the correct achine SERIAL NUMBER in any conversation or correspondence. Records of each machi e are filed by serial number. Given this number, the specific design and original equipment heck is accurate and quick.

ADDED IN ORMATION, when required, not found in this Manual or the Parts Book may be obtained from Marion Power Shove! Company, I nco at Marion, Ohio 43302.

SERVICE nd LABOR CHARGES are NOT accepted unless previously authorized by the Company i writing.

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 "EXCITA· TION", 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 LUB E 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. A 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.

M-4/M-5

CHECK OV R LOAD and thermal breakers. orrect supply of lubricant.

LEAR w\3lkways.

LOOK FOR loose bolts and locking devices.

KEEP FLO RS CLEAN and free of oil and grease. 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 inspect on or repair.

NEVER att mpt electrical repair, unless qualified.

HIGH VOL AGE power lines reguire using EXTREME CAlIfION.

Open pit mi ing equipment undergoes tremendous shock and stress. Marion's design considers these 10 ds. This machine, built with an ample reserve of power and strength, will meet the demand of its task. Marion's engineers cannot foresee the conditions imposed by abuse, neglect and ismanagement. These factors damage any piece of equipment more than years of continuo s operation and normal wear. Care, sound judgement and reason govern the economic n ed in the operation of power equipment.

Downtime ists, but an ongoing program of inspection and evaluatipn minimizes it. Awareness of unus al conditions generally warns personnel before breakdown occurs. Normal wear of machine parts escapes definition. Parts do not suddenly expire. Wear takes place at varying egrees over time. Constant checking indicates a wear pattern. A.n alert maintenance crew checks ALL structural members for evidence of stressed, broken or loose items. Minor crac s occur in steel structures. it's true of ALL machines. This is NOT SERIOUS when weld epaired while SMALL. Cold weiither causes faster expansion and brittleness than warm weatr er. Ear!y detection and quick repair prevents failure. A stretch, bend or defect often show up in condition of surface paint. A collection of dust along a line may indicate a crack in te meta!. Look closely at areas around openings where angles are Gut out. Also check guss t connections and points where thin and heavy metals join. The good crew watches for loose bolts, nuts, cap screws, lock washers and other locking devices. Rod bolts are import nt too. Signs of scuffed paint, worn or spots next to any part indicate movement nd becomes second nature to most personnel. Retighten ALL bolts shortly after initial start up. Grease and oil stqins often indicate problems. Perhaps just poor housekeeping, but at I ast something is wrong,

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 indicate 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 excessive wear or failure. Examine hydraulic hoses for early signs of failure.

Check oil level in hydraulic tank, check dirty filter indicators at full 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 lJutterflyvalves. Examine the main air piping for leaks. Check operatio'nof 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. Look at the condition o'f brake lining. Examine condition of propel brakes. Check auto-lube system for loose or broken fittings or injectors

Secure ALL guards and safety features in place. DISCONNECT POWER SOURCE with machine shut down so electrical crew may adequately clean and inspect motor generators and electrical cabinets. NOTE any discolored electrical parts is a sign of overheating. In humid areas, look for fungus and mildew. Dry compressed air 2t LOW pressure works well for dust removal. Clean corrosion from parts, joints and connections. Retighten, where needed, any loose connections and terminals. Use of proper tool here eliminates broken

terminpls an terminal blocks. Repla<;:e missing or damaged tags and labels. Bundle loose wiring. Fas n ALL components and wiring in Check the cable armor tight in the fixture. Lo k closely where wires and cables pass thru openings and grommets. Insulation damage gen rally 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 equi ment condition reports along the line is important also. Wear patterns show up at varying d grees in time. Recording and checking these reports at a future date allows comparison and lanned shutdowns. Planned repairs, part orders and crews for a scheduled ?hutdown elimin tes idle downtime.

A good trou leshooter attack plan includes:

Adequate pr paration including:

U derstanding the system and component function

S hematics and test data at hand

Q ality test equipment designed for the job

Preliminary nvestigation to determine effect of fault

Estimation f probable cause

Test to dete mine faulty component

Correction

Preventativ

SECTION 1

ENGINEERING DATA

The Marion machine design and construction follows rigid specifications in accordance to acceptable in ustry standards. This section provides information for proper machine maintenance and s considered confidential and in the interest of Marion Power Shovel Company, Inc. NOT : Consider the information in this section general in nature. inclIJdes established proc dures recommended by Marion Engineers which mayor may not wholly ClPply to your ma hine, but remains applicable by reference.

BRONZE LEEVE BUSHINGS assemble in bearing bosses with a light press fit.

Each FLA GE BUSHING secures thru flange with a minimum of four dowels, to restrict rotation o'f the sleeve. Dowel material is softer than bushing material.

Each STR IGHT SLEEVE BUSHING secures with four spring type straight slotted pin p0wels, eq ally spaced around outside diameter of bushing, between sleeve and boss.

eUSHING LI FE is figured on the table so that when running clearance exceeds three times the figure s own, replace the bushing,

BRONZE USHING REPLACEMENT first requires dismantling machinery and shaft frQrn Qrounq it. An air chisel or arc cutting torch to slit the bushing makes removal easier. Be careful not to CUT or SCaR E the bearirlg boss. CLEAN the boss completely. Remove ALL burrs. Bre k the bushing corner and lightly coat the outside of the bushing with white laad.

When a pr ss is unavailable; install the bushing using a long threaded rod, steel plates and a hollow cen er jack. Assemble these pieces as shown in the sketch. Then PU l,.L the pushing into place.

Tnre(1(fed Rolt

a:Jl.----- Threaded Boll

Steel Plate

Bredk Corner

• 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.