Bucyrus 59R Electric Blast Hole Drill Mechanical Maintenance Manual – CAT Rotary Track Drill 59R – PDF DOWNLOAD

Description

Bucyrus 59R Electric Blast Hole Drill Mechanical Maintenance Manual – CAT Rotary Track Drill 59R – PDF DOWNLOAD

DESCRIPTION:

Bucyrus 59R Electric Blast Hole Drill Mechanical Maintenance Manual – CAT Rotary Track Drill 59R – PDF DOWNLOAD

GENERAL

This section of the manual describes those aspects of preventive maintenance such as scheduled reports and safety precautions as they pertain to the 59-R drill.

MAINTENANCESCHEDULESAND 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. Scheduled 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 paperwork 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 evaluation

1. Is the problem one of normal wear?
2. Is the problem caused by machine application?
3. Is the problem a result of operator error?
4. Is the problem a result of unavoidable circumstances?
5. Is the problem of a repetitive nature?
6. By leaving the repairs to a later date, will any other component be affected?
7. Can repairs be accomplished immediately?
8. Will the cost of repairs immediately rather than later be worthwhile?
9. How long will the machine be down?

Once maintenance or repair has been scheduled, take the following points into consideration to minimize downtime and expense.

1. .Are all tools and equipment needed to accomplish maintenance or repair available on the job, and are they in good repair?
2.  Are all replacement parts on hand and readily available?
3. Is replacement of auxiliary parts, such as seals and bearings, necessary to accomplish repair, and have they been ordered?
4. Is all disassembly and reassembly data available?
5.  Have repair crews been scheduled?
6. Will there be adequate supervision on band for the repair crews?
7. Has the manufacturer been consulted for Service or Engineering assistance?
8. How long will the machine be down?

Once repair has been accomplished, the problem should again be reviewed with the following things in mind

1. Was the cause of the problem permanently corrected or just patched?
2. What guarantee is there the same problem will not occur again?
3. Is consultation with the manufacturer for design improvement necessary?
4. What costs were incurred in downtime, parts, tools and labor?
5. Could the problem have been prevented by prior action?

TABLE OF CONTENTS:

Bucyrus 59R Electric Blast Hole Drill Mechanical Maintenance Manual – CAT Rotary Track Drill 59R – PDF DOWNLOAD

COVER PAGE..................................................................................  1
TABLE OF CONTENTS...........................................................................  2
MECHANICAL MAINTENANCE......................................................................  7
	MAINTENANCE PROCEDURE...................................................................  7
		GENERAL.............................................................................  7
			MAINTENANCE SCHEDULES AND REPORTS...............................................  7
		SAFETY..............................................................................  9
			GENERAL.........................................................................  9
			IN-OPERATION MAINTENANCE........................................................  9
			PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK..................................  9
	LOWER WORKS............................................................................. 10
		CRAWLER BELTS....................................................................... 10
			ADJUSTMENT...................................................................... 10
			LINK REPLACEMENT................................................................ 12
			BELT REPLACEMENT................................................................ 13
		LOWER ROLLERS....................................................................... 14
		UPPER ROLLERS....................................................................... 15
		TAKE-UP TUMBLERS.................................................................... 16
		DRIVE TUMBLERS...................................................................... 17
		PLANETARY GEAR BOX.................................................................. 19
		CRAWLER FRAMES...................................................................... 21
		AXLES............................................................................... 23
	MAINFRAME............................................................................... 26
		MAINFRAME........................................................................... 26
		BIT VIEWING HATCH................................................................... 26
		MAST A-FRAME........................................................................ 27
		LEVELING JACKS...................................................................... 27
		MACHINERY HOUSE..................................................................... 30
		HOUSE VENTILATION FAN AND FILTER.................................................... 31
		WALKWAYS AND LADDERS................................................................ 31
		OPERATOR'S CAB...................................................................... 32
			OPERATOR'S SEAT................................................................. 32
			OPERATOR'S CONTROLS............................................................. 32
			VENTILATION UNIT................................................................ 32
		HYDRAULIC PUMP DRIVE................................................................ 33
		CABLE REEL.......................................................................... 35
			LEVEL WIND DRIVE ADJUSTMENT..................................................... 35
			HYDRAULIC ADJUSTMENTS........................................................... 35
			LUBRICATION..................................................................... 38
			HYDRAULIC MAINTENANCE........................................................... 38
			REPAIR.......................................................................... 38
	MAST.................................................................................... 42
		MAST STRUCTURE...................................................................... 42
		MAST SAFETY SLING................................................................... 43
		ROTARY GEARCASE..................................................................... 43
			DRIVE SHAFT ADJUSTMENT.......................................................... 43
			REPAIR.......................................................................... 44
		ROTARY MOTOR........................................................................ 49
		ROTARY COUPLING..................................................................... 49
		ROTARY SHOCK SUB.................................................................... 50
		ROTARY/PULLDOWN GUIDE FRAME......................................................... 52
			GUIDE ROLLER ADJUSTMENT......................................................... 52
			REPAIR.......................................................................... 52
		PULLDOWN GEARCASE................................................................... 56
		HOIST BRAKE......................................................................... 61
			INSPECTION...................................................................... 61
			BRAKE WEAR ADJUSTMENT........................................................... 61
			REPLACEMENT OF FRICTION DISCS................................................... 61
			DISASSEMBLY OF MAGNET BODY ARMATURE............................................. 62
			REASSEMBLY OF MAGNET BODY ARMATURE.............................................. 62
		PIPE RACKS.......................................................................... 63
		TOOL WRENCHES....................................................................... 64
		AUXILIARY WENCH..................................................................... 65
		MAST BRACES......................................................................... 65
			REPAIR.......................................................................... 65
			ADJUSTMENT...................................................................... 67
HYDRAULIC SYSTEM............................................................................ 68
	SYSTEM OPERATION........................................................................ 68
		CYLINDER CIRCUIT HYDRAULIC SYSTEM................................................... 68
		PROPEL CIRCUIT HYDRAULIC SYSTEM..................................................... 68
	GENERAL MAINTENANCE..................................................................... 70
		HYDRAULIC SYSTEM CLEANLINESS........................................................ 70
		OIL REQUIREMENTS.................................................................... 70
		OIL AND FILTER CHANGES.............................................................. 70
		FILTER MAINTENANCE.................................................................. 70
		WEEKLY MAINTENANCE CHECKS........................................................... 71
		OIL RESERVOIR REPAIRS............................................................... 71
		LEVELING JACK COUNTERBALANCE VALVE PRESSURE RELIEVING PROCEDURE..................... 71
			REAR JACKS...................................................................... 71
			FRONT JACKS..................................................................... 72
		PRE-START INSPECTION................................................................ 72
		HYDRAULIC SYSTEMS TESTS............................................................. 73
			PROPEL PUMP CHARGE PRESSURE CHECK............................................... 73
			CONTROL PRESSURE CHECK.......................................................... 73
			PROPEL ENABLE VALVE AND LOW SPEED SELECT CLOCK.................................. 73
			JACK CYLINDER CHECK IN MANUAL MODE.............................................. 74
			FLOW CONTROL CHECK.............................................................. 74
			JACK CYLINDER DRIFT TEST........................................................ 75
			BRAKE RELEASE PRESSURE CHECK.................................................... 75
			PROPEL BRAKE EMERGENCY RELEASE CHECK............................................ 75
			PROPEL PUMP MAIN RELIEF PRESSURE CHECK.......................................... 76
			CRAWLER FUNCTION CHECK.......................................................... 76
			BIT VIEWING HATCH CHECK......................................................... 76
			BOARDING STAIR CHECK............................................................ 76
			BREAKOUT WRENCH AND TOOL WRENCH CHECK........................................... 76
			DUST CURTAIN CYLINDERS.......................................................... 76
			DUST SEAL SLIDER................................................................ 76
			MAST LOCK....................................................................... 76
			MAST BRACE LOCK CYLINDERS....................................................... 76
			A-FRAME LOCK CYLINDERS.......................................................... 76
			MAST LOCK CONSTANT PRESSURE CHECK............................................... 76
			MAST BRACE CONSTANT PRESSURE CHECK.............................................. 76
			A-FRAME LOCK CONSTANT PRESSURE CHECK............................................ 76
			MAST RAISE/LOWER................................................................ 78
			AUXILIARY WENCH................................................................. 78
			HYDRAULIC CENTRAL LUBE DRIVE PRESSURE CHECK..................................... 79
			WINDOW GUARD FUNCTION CHECK..................................................... 79
			WATER INJECTION DRAIN VALVES CHECK.............................................. 79
			WATER INJECTION PUMP FUNCTION CHECK............................................. 79
			CHECK JACK IN AUTO LEVEL MODE................................................... 80
			PIPE RACK POSITION CHECK........................................................ 81
			PIPE RACK LOCK AND GATE CYLINDER PORT RELIEF SETTING............................ 81
			TEST POINT LOCATIONS............................................................ 82
AIR SYSTEM.................................................................................. 84
	SYSTEM OPERATION........................................................................ 84
		MAIN AIR SYSTEM..................................................................... 84
	GENERAL MAINTENANCE..................................................................... 85
		MAIN AIR SYSTEM..................................................................... 85
		INTAKE FILTER....................................................................... 85
		COMPRESSOR RADIATOR................................................................. 86
	ROTARY SCREW COMPRESSOR................................................................. 87
		DESCRIPTION......................................................................... 87
		COUPLING ALIGNMENT.................................................................. 87
		PARALLEL MISALIGNMENT............................................................... 88
		ANGULAR MISALIGNMENT................................................................ 88
	START-UP PROCEDURE...................................................................... 88
	SHUTDOWN................................................................................ 89
	CONTROLS AND INSTRUMENTS................................................................ 89
		AIR PRESSURE CONTROL SYSTEM......................................................... 89
		REDUCED UNLOADED HORSEPOWER FEATURE................................................. 94
		VARIABLE VOLUME FEATURE (OPTIONAL).................................................. 96
	LUBRICATION SYSTEM...................................................................... 97
		COMPRESSION OIL SYSTEM.............................................................. 97
		OIL SPECIFICATIONS.................................................................. 97
		FILLING OIL SYSTEM (INITIALLY)...................................................... 97
		OIL LEVEL GAUGE..................................................................... 97
		ADDING OIL BETWEEN CHANGES.......................................................... 98
		OIL CHANGE INTERVALS................................................................ 98
		DRAINING OIL SYSTEM................................................................. 98
		REFILLING OIL SYSTEM................................................................ 98
		COMPRESSOR OIL STRAINER AND FILTERS................................................. 98
		COMPRESSOR OIL COOLER............................................................... 99
		COMPRESSOR OIL SEPARATOR............................................................ 99
		COLD WEATHER START SYSTEM (OPTION)..................................................100
		AIR FILTERS.........................................................................100
		MAINTENANCE SCHEDULE................................................................102
DUST CONTROL................................................................................104
	GENERAL MAINTENANCE.....................................................................104
		DRILLING PLATFORMS AND DUST CURTAINS................................................104
		FILTER/CLONE SYSTEM (TIPTON)........................................................104
			DAILY MAINTENANCE CHECKS........................................................104
			MONTHLY MAINTENANCE CHECKS......................................................104
			SIX MONTH MAINTENANCE CHECKS....................................................105
		WATER INJECTION.....................................................................105
			OPERATION.......................................................................105
			DAILY MAINTENANCE CHECK.........................................................106
			WEEKLY MAINTENANCE CHECKS.......................................................106
			BIMONTHLY MAINTENANCE CHECKS....................................................106
			FLUID LEVELS....................................................................106
			SHAFT TO COUPLING ALIGNMENT.....................................................106
			FLOW CHART......................................................................106
		FILLING WATER TANK..................................................................107
		DECK WASHDOWN SYSTEM................................................................107
	MAINTENANCE OF FILTER/CLONE (TIPTON)....................................................108
		OPERATING PRINCIPLE.................................................................108
LUBRICATION.................................................................................110
	LUBRICATION PROCEDURES..................................................................110
		GENERAL.............................................................................110
		LUBRICATION CLEANLINESS.............................................................110
		LUBRICATION POINTS..................................................................110
		LUBRICATION BENCHMARKS..............................................................117
	LINCOLN AUTOMATIC SYSTEM................................................................118
		TROUBLESHOOTING SYSTEMS.............................................................118
			AIR LOCKS.......................................................................118
			DIRTY SUPPLY LINES..............................................................118
			ALL INJECTORS DO NOT FUNCTION PROPERLY..........................................118
			AFTER VENTING, INDICATOR STEMS ON INJECTORS DO NOT RETURN TO NORMAL POSITION....118
			FAILURE OF PUMP TO BUIL UP PRESSURE.............................................119
			SLWO PRESSURE RISE..............................................................119
			PUMP OPERATION..................................................................119
		PUMP DISASSEMBLY AND REASSEMBLY.....................................................119
			LUBRICATION.....................................................................122
TROUBLE SHOOTING............................................................................124
APPENDICES..................................................................................133
	GEAR INSPECTION.........................................................................133
	BOLT TORQUING...........................................................................135
		TORQUE WRENCH METHOD................................................................135
		TURN-OR-THE-NUT METHOD..............................................................136
	PINION, BRAKE DRUM, AND COUPLING INSTALLATION...........................................137
		REMOVAL FROM SHAFT..................................................................137
		MOUNTING ON SHAFT...................................................................137
	LUBE BENCHMARKS.........................................................................140
		MPG- MULTI PURPOSE TYPE GREASE......................................................140
		ACSL- AIR COMPRESSOR (SCREW TYPE) LUBRICANT.........................................141
		DPTL- DRILL PIPE THREAD LUBRICANT...................................................142
		MPO- MULTI-PURPOSE OIL..............................................................143
		OGL- OPEN GEAR LUBRICANT............................................................144
		RGL- REGULAR TYPE GEAR LUBRICANT....................................................146
		RWRL- RUNNING WIRE ROPE LUBRICANT...................................................149
		SPECIAL REQUIREMENTS................................................................149
		HYDO- HYDRAULIC OIL.................................................................150
	PROCEDURES, MAINT. WELDING, PRINCIPAL STRUCTURES ON BLAST HOLE DRILLS...................153
		GENERAL.............................................................................153
		MAINTENANCE WELDING.................................................................153
		STRUCTURAL MATERIALS................................................................153
		WELDING ELECTRODES..................................................................154
		PREHEAT REQUIREMENTS................................................................154
		REMOVAL OF CRACKS...................................................................155
		WELD GROOVE PREPARATION.............................................................155
		DRILL PIPE WELDING..................................................................156
		WELDING TECHNIQUE...................................................................157
		WELD INSPECTION.....................................................................157
		REPAIR OF BROKEN PARTS..............................................................157
	PREVENTIVE MAINTENANCE CHECKLIST........................................................158
		LEVEL 1 INSPECTION..................................................................158
		LEVEL 2 INSPECTION..................................................................162
		LEVEL 3 INSPECTION..................................................................164
	SPECIAL FITS............................................................................165

BUCYRUS 59R ELECTRIC BLAST HOLE DRILL MECHANICAL MAINTENANCE MANUAL – CAT ROTARY TRACK DRILL 59R – PDF DOWNLOAD:

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