CAT Bucyrus 49-RIII Blast Hole Drill Mechanical Maintenance Manual BI115938 – PDF DOWNLOAD

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CAT Bucyrus 49-RIII Blast Hole Drill Mechanical Maintenance Manual BI115938 – PDF DOWNLOAD

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CAT Bucyrus 49-RIII Blast Hole Drill Mechanical Maintenance Manual BI115938 – PDF DOWNLOAD

Language : English
Pages : 196
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus 49-RIII Blast Hole Drill Mechanical Maintenance Manual BI115938 – PDF DOWNLOAD

FOREWORD:

• The purpose of this manual is to provide information concerning the general maintenance of the
  49-RIII Rotary Blast Hole Drill.
• The Model 49-RIII 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 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 conseq!lences of each
  method. It is therefore extremely important that anyone who uses a service procedure or tool
  which is not recommended by Bucyrus 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, 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-RIII Blast Hole Drill Mechanical Maintenance Manual BI115938 – PDF DOWNLOAD

CHAPTER 1 MECHANICAL MAINTENANCE
SECTION 1 – MAINTENANCE PROCEDURE 1-1-1
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 1-2·1
Crawler Belts 1-2-1
Adjustment 1-2-2
Link Replacement 1-2-3
Belt Replacement 1-2-3
Lower Rollers 1-2-4
Repair 1-2-4
Upper Rollers 1-2-5
Repair 1-2-5
Take-Up Tumblers 1-2-6
Repair 1-2-6
( Drive Tumbler 1-2-7
Repair 1-2-7
Planetary Gearbox 1-2-8
Crawler Frames 1-2-10
Repair , 1-2-10
Axles 1-2-12
Repair 1-2-12
SECTION 3 – MAINFRAME 1·3·1
Mainframe ‘ 1-3-1
Repair 1-3-1
Bit Viewing Hatch 1-3-1
Repair 1-3-2
Mast A-Frame : 1-3-2
Repair : 1-3-2
Leveling Jacks 1-3-2
Repair 1-3-4
Machinery House 1-3-6
Repair 1-3-6
House Ventilation Fan and Filter 1-3-6
Walkways and Ladders ; 1-3-8
Operator’s Cab 1-3-9
Operator’s Seat 1-3-9
Operator’s Controls 1-3-9
Air Conditioning Unit 1-3-9
Hydraulic Pump Drive 1-3-9
Cable Reel 1-3-11
Level Wind Drive Adjustment 1-3-11
Hydraulic Adjustments 1-3-14
Lubrication 1-3-17
BI115938
Hydraulic Maintenance 1-3-17 (”
Repair 1-3-17 \
SECTION 4 – MAST , · 1·4·1
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 (Optional) 1-4-9
Repair 1-4-9
Rotary Shock Coupling 1-4-10
Repair 1-4-10
Rotary Shock Coupling 1-4-11
Repair ; 1-4-12
Rotary/Pulldown Guide Frame 1-4-13
Guide Roller Adjustment 1-4-13
Repair 1-4-13
Pulldown Gearcase 1-4-17
Repair 1-4-17
Hoist Brake 1-4-22
Inspection 1-4-22
Brake Wear Adjustment 1-4-23
Replacement of Friction Discs 1-4-23 (-
Disassembly of Magnet Body and Armature 1-4-24
Reassembly of Magnet Body and Armature 1-4-24
Pipe Racks ” 1-4-25
Repair : 1-4-25
Tool Wrenches ; 1-4-28
Repair 1-4-28
Breakout Wrench 1-4-29
Repair , 1-4-29
Adjustment 1-4-29
Auxiliary Winch 1-4-30
Mast Braces ” 1-4-30
Repair ” , 1-4-31
Adjustment 1-4-31
CHAPTER 2 HYDRAULIC SYSTEM
SECTION 1 – SYSTEM OPERATION 2·1·1
Cylinder Circuit ; 2-1-1
Propel Circuit ; 2-1-1
SECTION 2 – GENERAL MAINTENANCE 2-2-1
Hydraulic System Cleanliness 2-2-1
Oil Requirements 2-2-1
Oil and Filter Changes , 2-2-1
Weekly Maintenance Checks 2-2-1
( SECTION 3 – ROTARY SCREW COMPRESSOR
(A-C COMPRESSOR CORP KS-31-AC(X) OR KS-27-AC) 3-3-1
Description 3-3-1
Coupling Alignment 3-3-2
Parallel Misalignment 3-3-2
Angular Misalignment 3-3-3
Start-Up Procedure 3-3-3
Shutdown 3-3-5
Controls and Instruments 3-3-5
Air Pressure Control System 3-3-5
Variable Volume Feature (Optional) 3-3-9
Lubrication System : 3-3-9
Compressor Oil System : 3-3-9
Lubrication – compressor ; 3-3-10
Lubricant Specifications 3-3-10
Filling Oil System (Initially) 3~3-10
Oil Level Gauge 3-3-10
Adding Oil Between Changes 3-3-10
Draining Oil System 3-3-12
Refilling Oil System 3-3-13
Compressor Oil Strainer and Filters 3-3-13
Compressor Oil Cooler : 3-3-13
Temperature Control Valve 3-3-14
Compressor Oil Separator Elements 3-3-15
Air Filters 3-3-16
Maintenance Schedule 3-3-18
Preventative maintenance 3-3-19
Intake Valve Service (figure 3-3-16) 3-3-19
Air End Input Shaft Oil Seal Replacement (figure 3-3-17) 3-3-21
CHAPTER 4 DUST CONTROL
SECTION 1 – GENERAL MAINTENANCE 4-1-1
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 System 4-1-2
Operation 4-1-2
Filling Water Tank 4-1-3
Deck Washdown System (Optional) 4-1-3
Operating Principle 4-2-1
SECTION 2 – MAINTENANCE OF FILTER/CLONE® (TIPTON) 4-2-1
Maintenance 4-2-1
CHAPTER 5 LUBRICATION
SECTION 1 LUBRICATION PROCEDURES 5-1-1
General 5-1-1
Lubricant Cleanliness 5-1-1
Lubrication Points : 5-1-1
Lubrication Benchmarks 5-1-8
Rear Jacks 2-2-2
Front Jack 2-2-2
Prestart Inspection 2-2-3
Hydraulic Systems Tests 2-2-3
Propel Pump Charge Pressure Check 2-2-4
Control Pressure Check 2-2-4
Propel Enable Valve and Low Speed Select Check 2-2-4
Jack Cylinder Check in Manual Mode 2-2-5
Flow Control Check 2-2-5
Jack Cylinder Drift Test 2-2-6
Brake Release Pressure Check 2-2-6
Propel Brake Emergency Release Check 2-2-6
Propel Pump Main Relief Pressure Check 2-2-7
Crawler Function Check 2-2-7
Bit Viewing Hatch Check 2-2-7
Boarding Stair Check 2-2-7
Main Flow Valve Check 2-2-7
Breakout Wrench and Tool Wrench Check 2-2-8
Dust Curtain Cylinders 2-2-8
Dust Seal Slider 2-2-8
Mast Lock 2-2-8
Mast Brace Lock Cylinders 2-2-8
A-Frame Lock’ Cylinders 2-2-8
Mast Lock Constant Pressure Check 2-2-8
Mast Brace Constant :pressure Check 2-2-8 (
A-Frame Lock Constant Pressure Check 2-2-9
Mast Raise/Lower 2-2-9
Auxiliary Winch 2-2-9
Hydraulic Central Lube Drive Pressure Check 2-2-10
Window Guard Function Check 2-2-10
Water Injection Drain Valves Check 2-2-10
Water Injection Pump Function Check 2-2-11
Water Injection Washdown Check 2-2~12
Check Jacks in Auto Level Mode , 2-2-12
Pipe Rack Position Check 2-2-13
Pcipe Rack Lock and Gate Cylinder Port Relief Setting 2-2-13
Pipe Thread Lubricator Check 2-2-13
Pipe Positioner Function Check 2-2-13
Center Guide Function Check plus Constant Pressure Check 2-2-13
Automatic breakout wrench check 2-2-14
CHAPTER 3 AIR SYSTEM
SECTION 1- SYSTEM OPERATION’ 3-1-1
Main Air System 3-1-1
SECTION 2 – GENERAL MAINTENANCE 3·2·1
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
BI115938
SECTION 2 – LINCOLN AUTOMATIC SYSTEM 5-2-1
( Troubleshooting Systems 5-2-1
Air Locks 5-2-1
Dirty Supply Lines 5-2-1
All Injectors Do Not Work Properly 5-2-1
After Venting, The Indicator Stems on the Injectors do not Return to
Their Normal Position 5-2-1
Graco Pump Servicing 5-2-2
‘ Pressure Relief Procedure 5-2-2
Replacing the Throat Seals 5-2-2
Disconnecting the Reciprocator and Displacement Pump 5-2-2
Lubrication 5-2-10
APPENDIX Al GEAR INSPECTION lA-1
General lA-1
APPENDIX A2 – BOLT TORQUING 2A·I
Torque Wrench Method : 2A-1
Turn Of The Nut Method 2A-2
APPENDIX A3 – PINION, BRAKE DRUM AND COUPLING INSTALLATION •• •••••••• 3A-l
Removal From Shaft 3A-I
Mounting On Shaft 3A-1
APPENDIX A4 LUBE BENCHMARKS 4A-l
MPG – Multi-Purpose Type Grease 4A-1
Scope 4A-1
Application 4A-1
General Requirements 4A-1
Compounding 4A-1 (
Specific Requirements 4A-1
Notations 4A-1
Air Compressor (Screw Type) Lubricant 4A-2
DPTL – Drill Pipe Thread Lubricant 4A-2
Scope 4A-2
Application 4A-2
General Requirements 4A~2
Specific Requirements 4A-2
MPO – Milti-Purpose Oil 4A-3
Scope 4A-3
Application 4A-3
General Requirements 4A-3
Viscosity Recommendations 4A-3
OGL – Open Gear Lubricant 4A-3
Scope 4A-3
Application 4A-3
Methods of Application 4A-3
General Requirements 4A-3
Type of Lubricants 4A-4
Compounding 4A-4
Specific Requirements for all Types of Lubricants 4A-4
RGL – Regular Type Gear Lubricant 4A-5
Scope 4A-5
( Application 4A-5
General Requirements 4A-5
Compounding 4A-5
Viscosity and Viscosity Index 4A-5
BI115938
Notations 4A~6 (
Rotary Blast Hole Drills ~ 4A-6
Notations 4A-7
RWRL – Running Wire Rope Lubricant 4A-8
Scope ; 4A-8
Application 4A-8
General Requirements : 4A-8
Compounding 4A-8
Special Requirements 4A-8
HYDO – Hydraulic Oil 4A-9
PAO Synthetic Hydraulic Fluid 4A-9
Parafinnic base Petroleum Hydraulic Fluid 4A-IO
APPENDIX A5 – RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING
OF PRINCIPAL STRUCTURES ON BLAST HOLE DRILLS 5A·1
APPENDIX A6 PREVENTIVE MAINTENANCE CHECK LIST 6A·1
APPENDIX A 7 IIIfi SPECIAL FITS 7 A·1
APPENDIX AS AERO QUIP ORS CONNECTIONS SA·1

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