Cat Bucyrus M-4 & M-5 BLAST HOLE DRILL MAINTENANCE AND OPERATION MANUAL 2062 – PDF DOWNLOAD

Technical Manual

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M-4 & M-5

BLAST HOLE DRILL MAINTENANCE AND OPERATION

• DUE TO THE DANGERS INHERENT IN THE OPERATION OF ANY HIGH VOL TAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM SHOULD INCLUDE GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUlTY CHECK SYSTEM IS ALSO RECOMMENDED.

• PERSONNEL MUST NOT BE PERMITTED UNDER THE MACHINE NEAR THE DRILLMAIN 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.

AThis symbol is used to attract your attention to certain procedures that could cause personal injury or machine damage if proper precautions are not taken.

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

CAUTION:

• CLEANLINESS OF THE HYDRAULIC SYSTEM IS ESSENTIAL FOR RELIABLE OPERATION. FILL ONLY WITH CLEAN FILTERED OIL. REPLACE PLUGGED FI LTER ELEMENTS IMMEDIATELY. CONTAMINATES IN THE 01 L MAY RESULT IN DAMAGE TO HYDRAULIC SYSTEM COMPONENTS. THE MANUFACTURER WILL NOT BE RESPONSIBLE FOR FAILURES DUE TO HYDRAULIC SYSTEM CONTAMINATION.

• COMPONENTS SUCH AS PUMPS, MOT08S, AND CYLINDERS ARE SUBJECT TO WEAR AND MUST BE PERIODICALLY hcBUILT. THIS IS A NORMAL MAINTENANCE PROCEDURE AND MUST BE DONE ACCORDING TO THE INSTRUCTIONS IN THE FOLLOWING SECTIONS. USE ONLY REBUILD KITS SUPPLIED BY THE MANUFACTURER. OBSERVE PROPER STORAGE AND HANDLING PROCEDURES FOR COMPONENTS AND REBUILD KITS. THE MANUFACTURER WILL NOT BE RESPONSIBLE FOR FAILURES CAUSED BY IMPROPER STORAGE, HANDLING, OR ABUSIVE TREATMENT OR REPLACEMENT PARTS.

• OBSERVE EXTREME CAUTION WHEN STARTING MACHINE, PARTICULARLY IN COLD WEATHER. IMPROPER START-UP PROCEDURE MAY RESULT IN DAMAGE TO HYDRAULIC COMPONENTS. THE MANUFACTURER WI LL NOT BE RESPONSIBLE FOR DAMAGE INCURRED IN THIS WAY.

• THE MANUFACTURER IS NOT RESPONSIBLE FOR LOSSES INCURRED DUE TO COMPONENT DETERIORATION. IT IS THE OWNER'S RESPONSIBILITY TO PREVENT THIS DETERIORATION FROM OCCURRING.

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

ADDED INFORMATION not found in ths Manual or the Parts Book may be obtained from Marion Division of INDRESCO Inc., 617 West Center Street, P. O. Box 505, Marion, Ohio 43302.

REPAIR/SPARE PARTS WARRANTY

: Marion Division of INDRESCO Inc. 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 OFALL OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS.

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.

I THE FOREGOING IS MARION'S ONLY OBLIGATION AND BUYER'S EXCLUSIVELY REMEDY i I FOR BREACH OF WARRANTIES AND, EXCEPT FOR GROSS NEGLIGENCE, WILLFUL

j MISCONDUCT, OR REMEDIES PERMITTED UNDER THE PERFORMANCE, INSPECTION, ! I:. AND ACCEPTANCE CLAUSE OF MARION'S TERMS AND CONDITIONS, THE FOREGOING j,.' 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.

IN NO EVENT (INCLUDING, BUT NOT LIMITED TO, AVOIDANCE OF THE ABOVE LIMITED WARRANTIES AND REMEDIES) SHALL BUYER BE ENTITLED TO ANY INDIRECT, SPECIAL, INCIDENTAL 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 LIABILITY) 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

Marion M-4 & M-5 Drill

- Table of Contents -

SECTION 1- INTRODUCTION

SECTION 2- OPERATION

SECTION 3- MECHANICAL ADJUSTMENT

SECTION 4- HYDRAULIC SYSTEMS

SECTION 5- DRILL AIR SYSTEMS

SECTION 6- AUXILIARY AIR SYSTEM

SECTION 7- LUBRICATION

SECTION 8- ENGINEERING DATA

SECTION 9- ELECTRICAL

SECTION 10 - INSPECTION REPORTS

SECTION 1 INTRODUCTION

The Marion Rotary Blast Hole Drill uses a tri-cone rock bit for the drilling of holes to accept anexplosive material. The denotation of the "charge" breaks the rock and loosens the overburden. The rotary bit threads to a bit stabilizer or bit sub which threads on to a drill pipe section that threads into a crossover sub in the rotary gear box and is driven by one or two direct current electric motor(s) on the rotary gear box in the mast. The rotary gear box provides torque and rotary speed to the drill bit. A roller chain hoist-pulldown system, powered by two hydraulic motors, raises and lowers the rotary gear box and provides a load (or force) to the drill bit.

The machine is equipped with an independent propel system which uses a hydraulic motor on each crawler. The operator is afforded control of each crawler separately to permit excellent machine maneuverability.

The optional automatic (or semi-autolube) lubrication system provides lubrication to critical parts of the machine when in propel mode.

The drill air compressor(s) uses a rotary vane impeller or two screw rotors to supply air down thru the drill pipe and thru the drill bit. This bailing air cools the bearings in the drill bit and removes the drilled material cuttings from the hole.

The auxiliary air compressor provides pressurized air to operate the air valves and lubrication air pump. An additional discharge port is provided for attachment and use of air tools or hose for cleaning components or machinery house.

The hoist-pulldown and propel hydraulic circuits are included in the main hydraulic system. This system is powered by a 200 horsepower motor geared to two variable displacement axial piston pumps.

The auxiliary hydraulic system powers the support functions of the machine.

A house air filtering system provides clean air to the machinery house to cool the enclosed components and provide a slight pressurization to keep dust and dirt from entering. 1-1

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, but try to erase them quickly. Cleanliness and safety go together. A clean machine is easier to operate, inspect and maintain.

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

KNOW the location of fire extinguishers.

DO NOT DRI LL or PROPEL the machine without adequate air pressure.

DO NOT LEAVE the controls without pushing the OFF BUTTON marked "ROTATION", turning BOTH brake switches to "SET" and hoist-pulldown lever to the center detent position.

DO NOT SERVICE or lube moving parts.

PLEASE READ carefully this Manual, the Parts Book, and other manuals provided.

PLEASE LUBE regularly.

PLEASE CREATE A SYSTEMATIC maintenance procedure and follow it

PLEASE WATCH clearance when lowering mast

PLEASE OPE RATE 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 pulldown chains for early signs of wear or failure that may cause permanent damage.

CHECK LIMIT switches for proper operation.

MAINTAIN correct supply of lubricant

MAINTAIN CLEAR walkways.

LOOK FOR loose bolts and locking devices.

KEEP FLOORS CLEAN and free of oil and grease.

WIPE AWAY excess grease and oil around bearings and gears.

KE EP hands, feet and clothing away from moving parts.

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

NEVE R attempt electrical repair, unless qualified.

HIGH VOLTAGE power lines require using EXTREME CAUTION.

The information contained in this manual provides guidance to persons who are involved with the operation and maintenance of this machine. Needed data for operation, lubrication, adjustment and other tasks supplied in the various sections permits accurate operation and service. This information allows for quality maintenance when followed exactly.

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 machine; please contact your Local Service Representative or Service Department at Marion, Ohio. SERVICE and LABOR CHARGES are NOT accepted unless previously authorized in writing by Marion.

All enclosed specifications agree with the Marion Power Shovel Division Engineering Department

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 instruction in the front of it

All parts are listed by group number with items and part numbers for this SPECI F IC machine. Please order the correct parts in exact quantity. Parts ordered by mistake and returned are subject to a MPSD rehandling charge. RIGHT and LEFT HAND PARTS or direction on the machine correspond to the operator's hands at the controls as he faces the front or machinery house. 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 the original equipment check is accurate and quick.

SUGGESTIONS FOR INSPECTION

The Marion Rotary Blast Hole Drill design and manufacture offers the latest in mining equipment standards. This machine will provide many years of service and production when afforded proper usage and maintenance. Following correct maintenance procedures is a primary requirement to achieve long trouble free service. Sections within this maintenance manual and other manuals provided explain the necessary steps to achieve maximum component life, emphasizing correct adjustment procedures, proper lubrication to use for different operating conditions and how to avoid contamination of hydraulic oils.

To protect the hydraulic and air compressor systems from excessive wear or damage from contaminated oil or dirty air, protective filters are provided. These filters require periodic element replacement The condition of the hydraulic filters should be checked daily and changed as requ ired. I nstructions for check ing and changi ng the hydrau Iic filter elements are given in the hydraulic section of this manual. The air compressor intake filters should be checked daily and replaced when dirty. It is a good practice to replace the air compressor oil filter(s) at the same time the air intake filters are replaced.

Even with the best design, manufacture and maintenance possible; mechanical components with moving parts ultimately wear and require replacement. Friction forces, caused by metal to metal contact, cannot be completely eliminated even by the best lubricants and lube systems. This friction results in heat and component wear. Bearings ultimately wear out and shaft seals will leak. All rubber products ultimately, with age, lose their flexibility and requre replacement

Component rebuilding after some period of time elapses is inevitable. With the assistance of the Maintenance Manual and other technical material supplied, these components may be replaced and rebuilt for spares in the production parts warehouse, unless wear passes the tolerance permitting rebuilt performance adequate for reuse. This can be avoided with most components if wear is monitored by normal inspection and the wearing parts are replaced before irreparable damage is done. The manufacturer will not be responsible for damage incurred due to improper maintenance practices, including lack of inspection.

Parts that should be replaced during component rebuilding include: bushings, thrust washers, pins, V-belts, wear plates, brake linings, gaskets, o-rings, seals and other wearing parts. All components with moving parts have some wearing parts in them. Some of these components are: hydraulic cylinders, pumps, motors and valves, air cylinders and valves, solenoid valves, air compressor lubrication pump, brakes, rotary air joint, and breakout tong.

Some components are subjected to wear or flexing throughout all their life and eventually reach a point where they must be replaced or rebuilt Some of these items are roller chain, roller chain sprockets, crawler shoe sprockets, crawler shoes, crawler load rollers, winch cable, hydraulic and air hose, guide rollers and hydraulic accumulator.

Minor cracks eventually occur in all steel structures, therefore, the structural components (mast, main frame, and crawelr side frames) should be periodically inspected. The inspections should be made more frequently in cold weather (below a degree F) since steel will become brittle and more prone to fracture. Any cracks found in the structures should be weld repaired as soon as possible. Special attention should be given to the larger structural members, such as the main frame beams. Early detection and quick repair prevents failure. A stretch, bend, or defect often shows up in the condition of the surface paint. A collection of dust along a line may indicate a crack in the metal. Look closely at gusset connections and points where thin and heavy metals join. The manufacturer will not be responsible for damage incurred due to lack of structural inspections or improper weld repair.

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 MAIN reasons for breakdown. If any part shows wear or distortion beyond expected normal wear, order replacement and quickly install. The cost of repairs 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 7 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 gear box and propel gear box in each direction. Sound here may indicate damaged teeth on the gears. Check gear box for oil leakage and visually inspect all seals. Check oil level with dipstick.

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

Examine crawler 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 replace if necessary the inlet filter for the main air compressor. Check for proper operation of intake and discharge valves. Examine the main air piping for leaks. Check for proper lubrication. Check V-belt tension, if applicable, tighten or replace belts if needed.

• 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.