CAT Bucyrus 49-RII Electric Blast Hole Drill Mechanical Maintenance Manual BI379332 – PDF DOWNLOAD

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CAT Bucyrus 49-RII Electric Blast Hole Drill Mechanical Maintenance Manual BI379332 – PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus 49-RII Electric Blast Hole Drill Mechanical Maintenance Manual BI379332 – PDF DOWNLOAD

Language : English
Pages : 186
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus 49-RII Electric Blast Hole Drill Mechanical Maintenance Manual BI379332 – PDF DOWNLOAD

FOREWORD:

• The purpose of this manual is to provide information concerning the general maintenance of the 49-RII
  Rotary Blast Hole Drill.
• The Model 49-RII 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 necessary equipment to
  propel the drill. The mainframe includes the hydraulic system, main air system, and the machinery
  house. The machinery house encloses the majority of the mechanical equipment necessary for the
  main air system, 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, includes the operator’s station, and encloses 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 manual consists of six chapters, each divided into sections. A table of contents is located in the
  front of the manual.
• Throughout this manual the words CAUTION, WARNING and NOTE appear in bold face type.
  CAUTION is preceded by the safety alert symbol A and indicates that injury to personnel could
  occur if the proper procedures are not followed during operation or maintenance. Always read the
  CAUTION note carefully and use extreme care while performing that particular function.
• WARNING indicates a possible harzard to the machine or its components if the proper procedures
  are not followed. Whenever the word WARNING appears, special attention should be given to
  prevent possible equipment damage.
• NOTE is used to stress a point or to give additional information concerning the procedure being
  discussed.
• These CAUTION’s and WARNING’s are not all-inclusive. It is impossible for Bucyrus-Erie Company
  to know, evaluate, and advise maintenance and service personnel in every conceivable way a
  service operation might be performed and of the resulting possible hazardous consequences of each
  method. It is therefore extremely important that anyone who uses a service procedure or tool which
  is not recommended by Bucyrus-Erie Company to first satisfy himself that the service procedure or
  tool he chooses will not jeopardize his own safety, the safety of others, or cause machine or component
  damage. ·
• Every effort has been made to make this manual as complete and accurate as possible at the time
  of publication. Bucyrus-Erie Company, however, reserves the right to continually improve its products.
  For this reason changes may have been made to the machine or its equipment that are not
  detailed in this manual.

TABLE OF CONTENTS:

CAT Bucyrus 49-RII Electric Blast Hole Drill Mechanical Maintenance Manual BI379332 – PDF DOWNLOAD

CHAPTER 1 MECHANICAL MAINTENANCE
SECTION 1 – MAINTENANCE PROCEDURE
General 1-1-1
Maintenance Schedules and Reports 1-1-1
Safety 1-1-2
General 1-1-2
In-operation Maintenance 1-1-2
Precautions Before and During Maintenance Work 1-1-2
SECTION 2 – LOWER WORKS
Crawler Belts 1-2-1
Adjustment 1-2-1
Link Replacement 1-2-3
Belt Replacement 1-2-4
Lower Rollers 1-2-5
Repair 1-2-5
Upper Rollers 1-2-6
Repair 1-2-6
Take-up Tumblers 1-2-6
Repair 1-2-7
Drive Tumbler 1-2-8
Repair 1-2-8
Planetary Gearbox 1-2-8
Crawler Frames 1-2-11
Repair 1-2-11
Axles 1-2-12
Repair 1-2-13
SECTION 3- MAINFRAME
Mainframe 1-1-1
Repair 1-1-1
Bit viewing Hatch 1-1-1
Repair 1-1-2
Mast A-Frame 1-1-2
Repair 1-1-2
Leveling Jacks 1-1-2
Repair 1-1-4
Machinery House 1-1-5
Repair 1-1-6
House Ventilation Fan and Filter 1-1-7
Walkways and Ladders 1-1-7
Operator’s Cab 1-1-8
Operator’s Seat 1-1-8
Operator’s Controls 1-1-8
Ventilation Unit 1-1-9
Hydraulic Pump Drive 1-1-9
Cable Reel 1-1-11
Level Wind Drive Adjustment 1-1-12
Hydraulic Adjustments 1-1-12
Lubrication 1-1-12
Hydraulic Maintenance 1-1-14
Repair 1-1-14
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SECTION 4- MAST
Mast Structure 1-4-1 (
Repair 1-4-1
Mast Safety Slings 1-4-2
Repair 1-4-2
Rotary Gearcase 1-4-2
Drive Shaft Adjustment 1-4-3
Repair 1-4-3
Rotary Motor 1-4-8
Rotary Coupling 1-4-9
Repair 1-4-9
Rotary Shock Sub 1-4-10
Repair 1-4-10
Rotary/Pulldown Guide Frame 1-4-11
Guide Roller Adjustment 1-4-11
Repair 1-4-15
Pulldown Gearcase 1-4-16
Repair 1-4-16
Hoist Brake 1-4-20
Inspection 1-4-20
Brake Wear Adjustment 1-4-20
Replacement of Friction Discs 1-4-21
Disassembly of Magnet Body and Armature 1-4-21
Reassembly of Magnet Body and Armature 1-4-21
Pipe Racks 1-4-22
Repair 1-4-22
Tool Wrenches 1-4-23
Repair 1-4-25
Casing Tong Jib Crane 1-4-26
Pipe Positioner 1-4-26
Auxiliary Winch 1-4-26
Mast Braces 1-4-26
Repair 1-4-26
Adjustment 1-4-26
CHAPTER 2 HYDRAULIC SYSTEM
SECTION 1- SYSTEM OPERATION
Cylinder Circuit Hydraulic System 2-1-1
Propel Circuit Hydraulic System 2-1-1
SECTION 2 – GENERAL MAINTENANCE
Hydraulic System Cleanliness 2-2-1
Oil Requirements 2-2-1
Oil and Filter Changes 2-2-1
Weekly Maintenance Checks 2-2-1
Oil Reservoir Repairs 2-2-2
Pre start Inspection 2-2-2
Hydraulic Systems Tests 2-2-2
Propel Pump Charge Pressure Check 2-2-2
Control Pressure Check 2-2-3
Propel Enable Valve and Low Speed Select Check 2-2-3
Jack Cylinder Check in Manual Mode 2-2-3
Flow Control Check 2-2-4
Jack Cylinder Drift Test 2-2-4
Brake Release Pressure Check 2-2-4
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Propel Brake Emergency Release Check 2-2-4
Propel Pump Main Relief Pressure Check 2-2-5
Crawler Function Check 2-2-5
Bit Viewing Hatch Check 2-2-5
Boarding Stair Check 2-2-5
Main Flow Valve Check 2-2-5
Breakout Wrench and Tool Wrench Check 2-2-5
Dust Curtain Cylinders 2-2-5
Dust Seal Slider 2-2-6
Mast Lock (Station 6 of 7 -station manifold) 2-2-6
Mast Brace Lock Cylinders (Station 4 of 7-station manifold) 2-2-6
A-Frame Lock Cylinders (Station 5 of 7 Station Manifold) 2-2-6
Mast Lock Constant Pressure Check 2-2-6
Mast Brace Constant Pressure Check 2-2-6
Mast Raise/Lower 2-2-6
Auxiliary Winch 2-2-7
Pipe Rack Position 2-2-7
Pipe Rack Lock and Gate Cylinder Port Relief Setting 2-2-7
Check Jacks in Auto Level Mode 2-2-7
Hydraulic Lube Drive Pressure Reducing Valve Setting 2-2-8
CHAPTER 3 AIR SYSTEM
SECTION 1- SYSTEM OPERATION
Main Air System 3-1-1
SECTION 2- GENERAL MAINTENANCE
Main Air System 3-2-1
General 3-2-1
Intake Air Filter 3-2-1
Filter Replacement 3-2-1
Compressor Radiator 3-2-2
SECTION 3 – ROTARY SCREW COMPRESSOR
(A-C COMPRESSOR CORP KS-31-LU OR KS-27-LU)
Description 3-3-1
Coupling Alignment 3-3-1
Parallel Misalignment 3-3-2
Angular Misalignment 3-3-2
Start-Up Procedure 3-3-2
Shutdown 3-3-3
Controls and Instruments 3-3-3
Air Pressure Control System 3-3-3
Reduced Unloaded Horsepower Feature 3-3-8
Variable Volume Feature (Optional) 3-3-10
Lubrication System 3-3-11
Compression Oil System 3-3-11
Oil Specifications 3-3-12
Filling Oil System (Initially) 3-3-12
Oil Level Gauge 3-3-12
Adding Oil Between Changes 3-3-12
Oil Change Intervals 3-3-12
Draining Oil System 3-3-12
Refilling Oil System 3-3-13
Compressor Oil Strainer and Filters 3-3-13
Compressor Oil Cooler 3-3-14
BI379332
Thermostatic Control Valve 3-3-14
Compressor Oil Separator 3-3-15
(
Cold Weather Start System 3-3-15
Air Filters 3-3-17
Maintenance Schedule 3-3-19
CHAPTER 4 AIR SYSTEM
SECTION 1 – GENERAL MAINTENANCE
Drilling Platforms and Dust Curtains 4-1-1
FILTER/CLONE® System (Tipton) 4-1-1
Daily Maintenance Checks 4-1-1
Monthly Maintenance Checks 4-1-1
Six Month Maintenance Checks 4-1-2
Water Injection 4-1-2
Operation 4-1-2
SECTION 2 – MAINTENANCE OF FILTER/CLONE® (TIPTON)
Operating Principle 4-2-1
Maintenance 4-2-1
CHAPTER 5 LUBRICATION
SECTION 1 – LUBRICATION PROCEDURES
General 5-1-1
Lubricant Cleanliness 5-1-1
Lubrication Points 5-1-1
Lubrication Benchmarks 5-1-8
SECTION 2 – LINCOLN AUTOMATIC SYSTEM
Troubleshooting Systems 5-2-1
Air Locks 5-2-1
Dirty Supply Lines 5-2-1
All Injectors Do Not Function Properly 5-2-1
Mter Venting, the Indicator Stems on the Injectors Do Not Return to their
Normal Position 5-2-1
Failure of the Pump to Build Up Pressure 5-2-2
Slow Pressure Rise 5-2-2
Pump Operation 5-2-2
Pump Disassembly and Reassembly 5-2-2
Lubrication 5-2-5
CH APTER 6 TROUBLESHOOTING 6-l-1
APPENDICES
APPENDIX A1 – GEAR INSPECTION
General 1A-1
APPENDIX A2 – BOLT TORQUING
Torque Wrench Method 2A-1
Turn of the Nut Method 2A-2
APPENDIX A3 – PINION, BRAKE DRUM AND COUPLING INSTALLATION
Removal from Shaft 3A-1
Mounting on Shaft : 3A-1
BI379332
APPENDIX A4 – LUBE BENCHMARKS
MPG – Multi-Purpose Type Grease 4A-1
ACSL – Air compressor (Screw Type) Lubricant AA-2
CDL – Chain Drive Lubricant 4A-3
DPTL – Drill Pipe Thread Lubricant AA-4
MPO -Multi-Purpose Oil 4A-4
OGL- OPEN GEAR Lubricant 4A-5
RGL- REGULAR TYPE GEAR Lubricant AA-7
RWRL – RUNNING WIRE ROPE Lubricant AA-10
HYDO- HYDRAULIC OIL 4A-11
APPENDIX A5 -RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRINCIPAL
STRUCTURES ON BLAST HOLE DRILLS
General SA-1
Maintenance Welding SA-1
Structural Materials 5A-1
Welding Electrodes 5A-2
Preheat Requirements 5A-2
Removal of Cracks 5A-3
Weld Groove Preparation SA-3
Drill Pipe Welding , SA-4
Welding Technique 5A-5
Weld Inspection 5A-5
Repair of Broken Parts 5A-5
APPENDIX A6 – PREVENTIVE MAINTENANCE CHECK LIST
Level 1 Inspection 6A-1
Level 2 Inspection 6A-5
Level 3 Inspection 6A-7
APPENDIX A7- SPECIAL FITS 7A-1

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