CAT Bucyrus-Erie 49-R RH Electric Blast Hole Drill MECHANICAL MAINTENANCE MANUAL BI115936 – PDF DOWNLOAD

CAT Bucyrus-Erie 49-R RH Electric Blast Hole Drill MECHANICAL MAINTENANCE MANUAL BI115936 – PDF DOWNLOAD

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CAT Bucyrus-Erie 49-R RH Electric Blast Hole Drill MECHANICAL MAINTENANCE MANUAL BI115936 – PDF DOWNLOAD

Language : English
Pages :229
Downloadable : Yes
File Type : PDF

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CAT Bucyrus-Erie 49-R RH Electric Blast Hole Drill MECHANICAL MAINTENANCE MANUAL BI115936 – PDF DOWNLOAD
FOREWORD

• The purp0!3eof this manual is to provide information concerning the general maintenance of the 49-R rotary blast hole drilL The 49-R consists of three major units, the lower works, the mainframe and the mast. The lower works provides a foundation for the mainframe and contains the equipment necessary to propel the drilL The mainframe includes the hydraulic, main air and auxiliary air systems, and the machinery house.
• The machinery house encloses the majority of the mechanical equipment necessary for the main and auxiliary air systems, the hydraulic systems and electrical control systems. The machinery house is pressurized with filtered air to minimize dirt and heat build-up. The operator’s cab, mounted to the mainframe, provides the operator’s station, and enclosed the majority of the controls necessary to operate the drill.
• The mast contains the drill pipe and drilling tools, the pipe racks and the rotary and pulldown machinery. This man ua1 consists of six chapters, each divided into sections. A table of con ten ts is located in the front of the manual.

CHAPTERl
MECHANICAL MAINTENANCE
SECTION 1 – MAINTENANCE PROCEDURE

GENERAL

This section of the manual describes those aspects of preventive maintenance such as scheduled reports and safety precautions as they pertain to the 49-R drill.

MAINTENANCE SCHEDULES
AND REPORTS

• Ideally, all maintenance should be approached from the preventive standpoint and on a regularly scheduled basis. Obviously, this approach keeps downtime to a minimum and results in reduced maintenance costs. To establish a preventive upkeep program, scheduled inspections and an operator’s daily report are the most useful tools available. Schedule inspections should be conducted by the Mine Mechanical and Electrical Maintenance Departments since they are the most qualified.
• Either department should generate a certain amount of paper work such as inspection records that become a part of the mine’s permanent file on the machine. The inspection records should be explicit, complete, and cover every part of the machine. Each machine operator should complete a daily record of the machine’s performance.
• This record should include time worked, time down, reasons for all delays, and observations on any unusual conditions encountered during operation. From these records, items that can potentially cause machine downtime can be corrected or prevented immediately, or scheduled for a’ future date when the machine availability can be coordinated with the other mine activities.

Each problem should be thoroughly reviewed and . evaluated before scheduling any maintenance or repair. The following points should be considered during the evaluatio

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TABLE OF CONTENTS:

CAT Bucyrus-Erie 49-R RH Electric Blast Hole Drill MECHANICAL MAINTENANCE MANUAL BI115936 – PDF DOWNLOAD

CHAPTER 1 – MECHANICAL MAINTENANCE
PAGE
Section 1 -MECHANICAL PROCEDURE
General 1
Maintenance Schedules and Reports 1
Safety 2
General , 2
In-Operation Maintenance , 2
Precautions Before and During Maintenance Work , 2
Section 2 -LOWER WORKS
Crawler Belts ; 5
Adjustments Take-up Tumbler 5
Link Replacement : 6
BeltReplacement , ~ 7
Lower Rollers 7
Repair 8
Takeup Tumbler , 11
Repair ~ 9
Drive Tumblers 9
Repair 9
Planetary Gearbox 10
( Crawler Frames 14
Repair 14
Axles ; • 15
Repair ‘; 15
Section 3 – MAINFRAME
Mainframe 17
Repair 17
Mast A-Frame ‘ 17
Repair 17
Leveling Jacks 17
Repair 17
Machinery House 20
Repair , 21
House Ventilation Fan and Filter , ; : 21
Walkways and Ladders 21
Operator’s Cab : 22
Operator’s Seat ;22
Operator’s Controls
Ventilation Unit 22
Hydraulic Pump Drive 22
Cable Reel 24
Repair 25
Section 4 -MAST
Mast Structure 29
Repair , 29
Rotary Gearcase , 30
Drive Shaft Adjustment 30
Repair 30
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Rotary Motor 34
Rotary Coupling ~ 34
Repair , 34
(
Rotary Shock Sub , , 35
Repair 36
RotarylPulldown Guide Frame • 36
Guide Roller Adjustment 36
Repair 38
Pulldown Gearcase 40
Repair 40
Hoist Brake 44
Inspection 44
Adjustment 44
Repair ; 44
Pipe Racks 46
Repair 46
Tool Wrenches 46
Repair 48
Casing Tong Support 49
Pipe Positioner 49
Auxiliary Winch ; 51
Mast Braces , 52
Repair 52
Adjustment 52
CHAPTER 2 – HYDRAULIC SYSTEM (
Section 1 – SYSTEM OPERATION
Cylinder Circuit Hydraulic System 55
Propel Circuit Hydraulic System 56
Section 2 – GENERAL MAlNTENANCE
Hydraulic System Cleanliness 63
Oil Requirements 63
Oil and Filter Changes , 63
Weekly Maintenance Checks 63
Oil Reservoir Repairs 64
Prestart Inspection 64
Hydraulic System Tests 64
Propel Pump Charge Pressure (Rexroth Pumps only) 64
Propel Pump Charge Pressure (Sundstrand Pumps only) 64
Control Pressure Check ; 65
Propel Enable Valve and High Speed Select Check 65
Jack Cylinder Check In Manual Mode 65
Propel Brake Release Pressure Check 1 66
Left Track Main Relief Pressure Check (Rexroth Pumps only) 66
Left Track Main Relief Pressure Check (Sundstrand Pumps only) 67
Left Track Pressure Override Check (Rexroth Pumps only) 67
Left Crawler Track Sprocket RPM Check (Sundstrand Pumps only) 67
Right Track Main Relief Pressure Check (Rexroth Pumps only) 68
Right Track Main Relief Pressure Check (Sundstrand Pumps only) 68
Right Track Pressure Override Check (Rexroth Pumps only) 68 (
Right Crawler Track Sprocket RPM (Sundstrand Pumps only) 69
Propel Brake Emergency Release Check 69
Mast Latch Cylinders 69
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c
Dust Curtain Cylinders 69
A-Frame Latch Cylinders 69
Mast Brace Latch Cylinders : 69
Mast Hoist , 70
Auxiliary Winch : 70
Pipe Rack Position 70
Pipe Rack Lock and Gate Cylinder Port Relief Setting 70A
Cable Reel 70A
Leveling Jacks In Auto Level Mode 70A
Test Point Location Chart • 70B
Section 3 – COMPONENT MAlNTENANCE
Cylinder Circuit Hydraulic Pump Overhaul 71
General , 71
Single Pump Disassembly • 71
Singe Pump Inspection 72
Single Pump Assembly 73
Dual Pump Disassembly 74
Dual Pump Inspection 75
Dual Pump Assembly 75
Cable Reel Hydraulic Pump 77
General 77
Disassembly 78
Inspection 79
Assembly 79
Cable Reel Hydraulic Motor , 79
Disassembly ‘ ‘ 79
Cleaning and Inspection 81
Reassembly 81
Hydraulic Oil Cooler 82
Weekly Maintenance Check , 82
1000 Hour Maintenance Check 82
Yearly Maintenance Check 82
CHAPTER 3 – AIR SYSTEMS
Section 1 – SYSTEMS OPERATIONS
General 83
Main Air System , 83
Auxiliary Air System 83
Safety 83
Section 2 – GENERAL MAINTENANCE
Main Air System 87
General 87
Intake Air Filter – Box Type 87
Intake Air Filter – Tubular Type 87
Compressor Radiator 88
Auxiliary Air System 88
Auxiliary Air Compressor 88
Miscellaneous Components 89
Unloader Check Valve Service 89
Air Tanks ; 90
Air Tank Valves 90
Pressure Switch 90
Filter 90
Anti-Freezer 90
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Section ~is!~~~:’ ~~ ~~ ~~ ~ ~~~~ ~~~~~~~ ~~~ ~~~ ~~ ~~~~ 91 (
Fitting and REassembly 92
Section 4 – AUXILIARY AIR COMPRESSOR (COMPAIR-KELLOGG) B462
Head Value Service , 95
Piston Ring Service 95
Overhaul Procedure : 96
Reassembly 96
Section 5 – ROTARY VANE COMPRESSOR (A-C COMPRESSOR CORP )
1000 Hour Maintenance Check 99
4000 Hour Maintenance Check 100
Blade Protection in Idle Units 102
Rotor Alignment for Redoweling 102
Rotor Field Redoweling 103
Section 6 – ROTARY SCREW COMPRESSOR (A-C COMPRESSOR CORP )
Description 105
Coupling Alignment 105
Start-Up Procedure 106
Controls and Instruments 107
Lubrication System 113
Air Filters 119
Maintenance Schedule 120
CHAPTER 4 – TROUBLESHOOTING (
Section 1 – GENERAL MAINTENANCE
Drilling Platforms and Dust Curtains , 127
Filter/Clone® System (Tipton) 127
Daily Maintenance 127
Monthly Maintenance Checks 127
Six Month Maintenance Checks 127
Water Injection 128
Operation 128
Section 2 – MAINTENANCE OF FILTERICLONE® (TIPTON)
Operating Principles 129
Maintenance 129
CHAPTER 5 – LUBRICATION
Section 1 – LUBRICATION
General 131
Lubricant Cleanliness 131
Lubrication Points 131
Lubricant Benchmarks 132
Lubrication Charts
Gearcase and Reservoir Capacities 132
Lower Works 133
Mainframe 134
Mast (Part 1) 135
Mast (Part 2) 136
Mast (Part 3) 137
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Troubleshooting Systems 139
Air Locks 139
Dirty Supply Lines 139
All Injectors Do Not Function Properly 139
Mer Venting, the Indicator Stems on the Injectors
Do Not Return to Their Normal Position 139
Failure of Pump to Build Up Pressure 140
Sluggish Pump Operation , ~ 140
Slow Pressure Rise 140
Assembly of Tubing Compression Fittings 140
Principle of Operation – Pump Air Motor 140
Service of Lower Pumping Unit 142
Lubrication 143
Installation, Operating, and Maintenance Instructions ~ , 143
Section 3 – TRABON AUTOMATIC SYSTEM
Locating Blockage in System : 147
Terminology 147
Procedure 147
Torque Information in Foot Pounds : 150
Section 4 -VANE TYPE MAIN COMPRESSOR LUBRICATOR
Operation and Adjustinent 151
To Start Lubricator 151
To Adjust Lubricator 151
( Sight Feed Unit 151
Purging Oil From Pumping Unit 151
Care of Lubricator ; 152
CHAPTER 6 – TROUBLESHOOTING
General 153
prilling 153
Rotary Drive Unit : 155
Pulldown Unit 156
Pulldown Unit Hoist Brake 158
Mast 158
Main Air Compressor (vane type) 159
Main Air Compressor (screw type) : 161
Auxiliary Air Compressor 164
Hydraulic System 165
Hydraulic Oil Cooler 166
Hydraulic Cylinder : 167
Hydraulic Pump (Cylinder Circuit) 167
Hydraulic Pump (Propel Circuit)
Cable Reel Hydraulic Motor 169
Filter/Clone® 170
Appendix Al – GEAR INSPECTION 1A
AppendixA2 – BOLT TORQUING
Torque Wrench Method 3A
Turn-Of-The-NutMethod 4A
Appendix A3 – PINION, BRAKE DRUM, AND COUPLING INSTALLATION
Removal From Motor Shaft 5A
Mounting on Shaft 5A
Appendix A4 – LUBE BENCHMARKS
Multipurpose Type Grease (MPG) 9A
Air Compressor (vane type) Lubricant (ACVL) 10A
Air Compressor (screw type) Lubricant (ACSL) llA
Chain Drive Lubricant 12A
Drill Pipe Thread Lubricant (DPTL) 13A
Multipurpose Oil (MPO) 14A
Open Gear Lubricant (OGL) 14A
Regular Type Gear Lubricant (RGL) 16A
Running Wire Rope Lubricant (RWRL) 20A
General : 23A C·
Maintenance Welding 23A
Structural Materials 23A
Welding Electrodes 24A
Preheat Requirements 26A
Removal of Cracks 26A
Weld Groove Preparation 26A
Drill Pipe Welding 26A
Welding Technique 28A
Weld Inspection 28A
Repair of Broken Parts 28A
Methods of Repair of Cracks : 28A
Appendix A6 – PREVENTIVE MAINTENANCE CHECKLISTS
Levell Inspection ; 29A
Level II Inspection 34A
Level III Inspection 36A
Appendix A 7 – SPECIAL DRAWINGS (BEARING FITS)
Pulldown First Intermediate and Shipper Shaft 39A
Pulldown Input Shaft 39A
Pulldown Second Intermediate Shaft 39A
Rotary Gearcase Shafts 40A
Lower Guide Rollers 41A
Upper Guide Rollers and Shipper Shafts 41A

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