CAT MARION M-3 BLAST HOLE DRILL MAINTENANCE AND OPERATION MANUAL

Technical Manual

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This manual is divided into major sections covering various serviceable com· ponents and systems of the Rotary Blast Hole Drill. These sections and their contents are organized by thumb index tabs shown below and right - blue ink tabmarks. To use this manual, grasp the right hand side of the book between thumb and fingers. Bend pages back to find the start of the corresponding sections in this index tab.

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

GENERAL INFORMATION

This manual is designed to assist the owner in the operation and preventivemaintenance of this machine. Following easy to understand step-by-step procedures, maintenance personnel can perform these tasks in a safe manner. When a systematic and thorough maintenance/ service procedure (a responsibility of the maintenance superintendent) is used for machine, minimum unplanned downtime and reliable operation will result.

THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with item/part numbers for THIS SPECIFIC MACHINE. Order parts in exact quantity. Parts ordered by mistake and returned, are subject to a rehandling charge. and LEFT HAND PARTS on the upper frame correspond to the oJerator's hands at the controls; as seated when oPerating the machine: Please state the correct machine SERIAL NUMBER (located on a plate in the operator's cab) when corresponding or contacting factory service or parts departments. Records on each machine are filed by serial number and when given this number, your machine's specific design and original equipment is accessed quickly by the Marion parts representative.

Periodic additions or revisions may be made to this manual. These will be mailed direct to you from the factory. Should you require additional information or factory service assistance contact your regional service representative or

Service Department

Marion Power Shovel Division

Dresser Industries, Inc.

617 West Center Street

P.O. Box 505

Marion, OH 43302

or:

Telephone 614/383-5211

Telex 24-5307

TWX 810/487-2772

614/383-5211

It is Marion Power Shovel Division policy to improve its products whenever possible and practical to do so. Marion reserves the right to make changes or add improvements at any time without incurring any obligation to install such changes on machines sold previously.

Due to this continuous program of product research and development some procedures, specificatfons and parts may be altered in a constant effort to improve machines. 1-1

SAFETY PRECAUTIONS

AThis safety alert symbol is used here and throughout this manual to call your 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.

Be certain an)'one servicing this machine is aware of these SAFETY PRECAUTIONS. In the event you question your abil ity to safely perform any of the enclosed maintenance and operational procedures contact your regional Marion service representative or the factory.

The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.

ADANGER: Denotes extreme intrinsic hazard which exists and could result in high probability of death or irreparable injury if proper precautions are ignored.

AWARNING: Denotes a hazard exists which can result in injury or death if proper precautions are ignored.

ACAUTION: Denotes a reminder of safety practices or directs attention to unsafe practices which could result in personal injury if proper precautions are ignored.

An example of a safety alert symbol and special safety instructions is shown below.

ADANGER: Inherent danger exists in the operation of any high voltage electrical equipment. A safe grounding system includes ground conductors in 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.

Operating, maintaining or servicing this machine can be dangerous unless performed properly. 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. t-actory service representatives and specialists are available to provide additional information or technical assistance. 1-2

SAFETY PRECAUTIONS - continued

The operator must be alert, physically fit, and free from the influence of alcohol, drugs, or medications that might effect his eyesight, hearing or reactions.

Safety must always be the operator's most important concern. He must refuse to operate when he knows it is unsafe, and consurt his supervisor when safety is in doubt.

The owner, and/or operator must replace any and all safety and warning product graphics if they are defaced or removed from the machine.

Before doing any work on the machine, lock out or remove electric power supply from the machine and tag it so personnel are aware that someone is working on the machine.

Do not start an engine indoors unless adequate exhaust ventilators are provided. Once an engine is running, move the machine outdoors as soon as possible.

Keep hands, feet, clothing away from rotating parts.

Read carefully this manual, the parts book and provided.

Think before you act. Carelessness is one luxury the serviceman cannot afford.

Do not wear rings, wrist watches or loose fitting clothing when working on machinery. They could catch on moving parts causing serious injury. Never adjust and/or service a machine in bare feet, sandals or sneakers.

Always wear safety glasses when using a hammer, chisel or other tools that may cause chips to fly.

Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact, remove sealant or solvent promptly by washing with soap and water.

Always use a safety bar to block air or hydraulic operated cylinders. Never rely on the machine air or hydraulic systems to hold when working on machines. An air or hydraulic line or cylinder could fail or someone could accidently strike the control levers causing the equipment to fall.

Equipment must be level on ground at all times during machine servicing and periods of idleness.

Cranes and hoists must be of sufficient capacity to lift the heavier components (gear cases, dipper/bucket, boom, etc.) and have an ample safety margin. 1-3

SAFETY PRECAUTIONS - continued

Be sure heavy items are properly supported from cranes or hoists before removing supporting members from machine.

Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times.

Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they cou Id fai I.

Use safety catch on all hoist hooks. Do not take a chance, the load could slip off of the hook.

If a heavy item begins to fall, let it fall, don't try to catch it.

When disassembling machines, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.

Keep work area organized and clean. Wipe up oil or spills of any kind. Keep tools and parts off of the ground. i Eliminate l the possibility df a fall which could result in a serious injury.

Floors, walkways and stairways must be clean and dry. After draining operations be sure all spillage is cleaned up. Electrical cords and wet metal floors make a dangerous combination.

Check all wire ropes for telltale signs of early wear or failure. Look for and secure any loose bolts or locking devices.

Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless qualified. Check limit switches for proper operation.

When using an acetylene torch, always wear welding goggles and gloves. Keep a "charged" fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart. Do not weld or heat areas near transformers or electrical cabinets and utilize proper shielding around lubrication lines.

Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Then, be sure to wear safety glasses.

Be careful when using compressed air to dry parts. Use approved air blow guns, do not exceed 207 kPa (30 psi), wear safety glasses or goggles and use proper shielding to protect everyone in the work area. 1-4

PREVENTIVE MAINTENANCE - continued

ADANGER: REMOVE ELECTRICAL POWER FROM MACHINE BEFORE PERFORMING ANY OF THE FOLLOWING INSPECTIONS:

Inspect electrical cabinets; any discolored wires or components indicate overheating conditions have occured.

Look for moisture, fungus or mildew in electrical cabinets. If found clean with approved solvents only, or compressed air.

Check all electrical cabinets for messy or torn fasteners, cable armor or grommets, loose insulation

Inspect electrical motors for discolored commutators or worn brushes.

These inspection points are representative of typical preventive maintenance routines. Use Section 10 as a detailed guide for all areas of machine inspection and suggested scheduled periods.

*STANDARD WARRANTY

00000000000000

MarionPower Shovel Division, Dresser Industries, Inc. ("Marion") warrants that its products, when ship-

ped, for a period of six (6) months from the date of delivery, F.O.B. point of shipment, will meet ap-

plicable, 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 maintain-

ed. 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 OF ALL OTHER WARRANTIES WHATSOEVER, EX·

PRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES

OF MERCHANT ABILITY 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.

THE FOREGOING tiS MARION'S ONLY AND BUYER'S EXCLUSIVE REMEDY FOR BREACH

OF WARRANTY AND, EXCEPT FOR GROSS NEGLIGENCE OR WILLFUL MISCONDUCT, THE FOREGOING +:+

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 +t.

CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES. BUYER'S f

FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR 4.

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, INCIDENTIAL OR CONSE· •

•:. aUENTIAL 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 L1ABILI- .:•

TY) 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. .1.

y

Marion reserves the right to improve or change the design of its products and specifications thereof and .:•

•:. Marion shall incur no liability thereby or any obligations to install such improvements on products .:• •:. previously sold.

*The above warranty relates to spare/repair parts for the Marion equipment referenced in this document.

For specifics on the machine warranty, reference should be made to the purchase contract or Marion +:.

Power Shovel Division, Dresser Industries, Inc. may be contacted directly. Please identify machine serial .r number.

TRAINING

Qualified maintenance personnel using a scheduled maintenance program are the best way to minimize machine downtime and maximize productivity of equipment.

Marion offers factory and mine site maintenance seminars and special familiarization programs for mechanics, oilers, electricians and operators on a fee basis.

These programs are presented by qualified factory specialists and service technic,ians. Special customized training programs can also be developed to meet specific mine requirements.

Objectives of training and training materials are to provide the means for developing and maintaining on-site service repair capability. The Marion training programs use field proven concepts where your employees see, hear and participate in "hands on" practice of service repair operations.

For further information about Marion service training capabilities and programs contact:

Training Supervisor

Marion Power Shovel Division

P.O. Box 505 Marion, Ohio 43302

SECTION 2 OPERATION INDEX

SECTION 2 OPERATION

OPERATOR'S CAB is separated from the machinery and contains the primary controls and indicators for operating the This configuration minimizes noise and vibration in the operator's cab, resulting in less operator fatigue. Excellent visibility is provided to the drill table and propelling with large safety glass windows. Separate control panels are provided for drilling and propelling.

Look around the cab interior at the controls and familiarize yourself with their location. The what, how and when of the controls will be explained throughout this section.

The right and/or left direction in this section, correspond to the operator's hands as he faces the panels.

DRILLING CONTROL STATION, located at left front corner of the operator's cab, contains the controls for the drilling operation. The following number list identifies the items, on the panel, for easy location on sketch(s) provided.

A.CAUTION: Understand the operating procedures, sequences and controls before operating this machine..

ACAUTION: DO NOT OPEN top or side doors of Drilling Control station unless qualified to work on automatic drill control (ADe). 2-2

1. ANNUNCIATOR -A warning panel which relays vital equipment status information. Trouble is indicated with a flashing light and buzzer (item 20). Some functions are warning only; others will be automatically shut down. See Annunciator Panel on page 2 for more detail.

2. Blank cover plate.

3. HYD. PRESS. AUX. No.1 - Provides pressure reading for valve bank number 1 and 2 ofthe auxiliary hydraulic system. With no valves shifted pressure will be about 250 PSI.

4. HYD. PRESS. AUX. No.2 - Provides pressure reading for hoist/pull down brakes, propel brakes and upper stem rack latches of the auxiliary hydraulic system. Pressure will be about 400 PSI with no valves shifted.

5. CLOCK - The clock is an option.

6. AUXILIARY AIR PRESS. - Shows auxiliary air compressor output pressure. Reading should be 80 to 100 PSI. See Section 6 of this manual for information about this system.

7. ROTATION SPEED - Indicates the drill stem speed.

8. HOLE DEPTH - Indicates depth of hole. See items 15,16,17 and 21.

9. DRILLING AIR PRESS. - Indicates output air pressure of main air compressor with the stem air switch ON (item 25). Air pressure should be 25-35 PSI when drilling. See Section 5 of this manual for detail.

10. ROTATION TORQUE - Indicates percent of torque used by the D.C. motor on the rotary gear box (ammeter).

ACAUTION: CURRENT SHOULD NOT EXCEED 100 PERCENT FOR ANY EXTENDED TIME PERIOD to prevent motor overheating. Some overloading may occur, but in occasional cases. Use the following load values for the indicated time:

120 percent for 5 minutes

150 percentfor 1 minute

200 percent for 10 seconds

DO NOT REPEAT overload more than ONCE in 20 minutes.

11. ACK (Acknowledge) - Push button converts a flashing Iight(s) on the Annunciator Panel (item 1) to a steady light and silences warning buzzer item 20. 2-3

12. TEST - Push button to test the lights on the annnunciator. See Annunciator Panel for detail.

13. RESET - Push button to reset the lights on the annunciator panel. See Annunciator Panel.

14. PSI OR BIT LOAD - In DRILL MODE ONLY; move toggle switch up (PSI) for hydraulic system pressure (PSI) in hoist on item 18 and pull down on item 19. Move switch down (Bit Load) to read on item 19 actual weight on drill bit in pounds.

NOTE: Readouts can be obtained in English or Metric by the position of the top toggle switch located on the enclosed panel above.

15. IN ITIAL - This push button establishes base "0" on Hole Depth readout (item 8). Press this button AFTER the depth (of hole) is determined on item 16 and drill bit at ground line.

16. HOLE DEPTH - Adjustable indicator to set depth of hole to be drilled. Functional only in automatic drill mode.

17. ALARM - On/Off toggle switch to silence the depth beeper item 21.

18. HOIST L.H. CRAWLER - Indicates hydraulic pressure in the hoist direction OR pressure to the left hand crawler propel motor depending on the machine mode.

19. PULL DOWN R.H. CRAWLER - Indicates hydraulic pressure in the pull down direction OR pressure to right hand crawler propel motor if machine is in propel mode.

20. WARNING - This buzzer alerts the operator of a malfunction on the Annunciator Panel. Silence by depressing the ACK button.

21. DEPTH - This beeper sounds when the drill bit reaches the hole depth set on the Hole Depth indicator (item 16).

22. PROPEL - Red light indicates that the machine is in the propel mode and the Propel Control station is energized with item 23 in the propel mode.

23. HOIST/STANDBY/PROPEL SWITCH - This selector switch determines the drilling or propel mode, sets hoist brakes and energizes or de-energizes the leveling system.

PROPEL/LEVELING SET. This position automatically sets hoist brakes, deactivates the levers on the drilling control station and actuates the Propel Control Station. 2-4

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

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