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Cat Bucyrus 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL 10390 – PDF DOWNLOAD
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Cat Bucyrus 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL 10390 – PDF DOWNLOAD
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Description
Cat Bucyrus 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL 10390 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL 10390 – PDF DOWNLOAD
Language : English
Pages : 440
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL 10390 – PDF DOWNLOAD
SN: 141192
SN: 141201
Introduction
GENERAL INFORMATION
- This manual is designed to assist the owner in the operation and maintenance of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner. When a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
- THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material 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 the associated item/part numbers for THIS SPECIFIC MACHINE.
- Order parts in the exact quantity needed. RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please state the correct machine SERIAL NUMBER when corresponding or contacting the 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 Bucyrus International parts representative.
SAFETY
- The safety alert symbols displayed here and throughout this manual, are used to call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine
- . Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions. If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional Bucyrus service representative or the factory.
- The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL 10390 – PDF DOWNLOAD
10390_1.pdf……………………………………………………….. 0
10390_1.pdf……………………………………………………. 0
Table of Contents…………………………………………… 7
General Information …………………………………….. 9
Safety ………………………………………………… 10
SAFETY PRECAUTIONS ……………………………………… 11
FIRE PREVENTION CONSIDERATIONS …………………………… 14
STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS ……… 15
Warning signs and decals ………………………………… 18
Stored Energy Signs …………………………………….. 19
Machine Overview ……………………………………….. 20
Deck Plan ……………………………………………… 21
PROPEL MACHINERY ……………………………………….. 22
MAIN FRAME AND DECKS ……………………………………. 23
Machinery House ………………………………………… 24
MAIN AIR SYSTEMS ……………………………………….. 25
Air Compressor …………………………………………. 25
HYDRAULIC SYSTEM ……………………………………….. 26
OPERATOR’S CAB …………………………………………. 27
MAST ………………………………………………….. 28
Mast/Machinery …………………………………………. 28
Rotary Gearcase ………………………………………… 29
Pulldown Gearcase ………………………………………. 30
Drill Tool String Assembly ……………………………… 31
Breakout Wrench ………………………………………… 32
Cable Reel ……………………………………………. 32
TYPICAL MACHINE Specifications …………………………… 34
General Estimated COMPONENT WEIGHTS ………………………. 36
10390_2.pdf……………………………………………………….. 0
Table of Contents………………………………………………. 42
GENERAL INFORMATION ………………………………………… 46
OPERATION NEAR ELECTRICAL TRANSMISSION LINES …………………. 46
CONTROLS – LOCATION AND FUNCTION ……………………………. 47
OPERATOR’S CONTROL console ………………………………….. 48
OPERATOR’S CONTROL CONSOLE – OVERVIEW ………………………… 48
Main Control Panel ………………………………………… 49
MAIN CONTROL PANEL – OVERVIEW ……………………………….. 49
Hoist/Pulldown Rheostat …………………………………….. 49
Rotary Rheostat ……………………………………………. 50
Drill/Propel Controls ON and OFF Push-button ………………….. 50
Hoist/Pulldown Speed Selector Switch …………………………. 51
Rotary Speed Selector Switch ………………………………… 51
Hoist Brake Switch …………………………………………. 52
Pipe Rack Selector Switch …………………………………… 52
Pipe Rack Joystick (Left Crawler Propel) ……………………… 52
Winch/Mast Selector Switch ………………………………….. 53
Mast/Winch Joystick (Right Crawler Propel) ……………………. 53
Tool Wrench Switch …………………………………………. 54
Dust Curtain Switch ………………………………………… 54
Bit View Hatch Switch ………………………………………. 54
Propel Control Panel ……………………………………….. 55
PROPEL CONTROL PANEL – OVERVIEW ……………………………… 55
Emergency Stop Push-button (Optional) ………………………… 55
Propel Speed Selector Switch ………………………………… 56
Compressor Stop Push-button …………………………………. 56
Compressor Vent/Drill Switch ………………………………… 56
Heater/Vent/Air Conditioner Controls …………………………. 56
Operating Mode Selector Switch ………………………………. 56
Propel Joysticks …………………………………………… 57
Selector Switch Panel ………………………………………. 57
SELECTOR SWITCH PANEL – OVERVIEW …………………………….. 57
Breakout Wrench Switch ……………………………………… 58
Pipe Positioner Switch (Optional) ……………………………. 58
Dust Seal Switch (Optional) …………………………………. 58
A-Frame Lock Switch (Optional) ………………………………. 58
Mast Brace Lock Switch ……………………………………… 58
Mast Lock Switch …………………………………………… 59
Boarding Stairs Switch ……………………………………… 59
Pedestal Heater Switch (Optional) ……………………………. 59
Fire Suppression System Indicators (Optional) …………………. 59
RADIO (Optional) …………………………………………… 59
Leveling Control Panel ……………………………………… 60
LEVELING CONTROL PANEL ……………………………………… 60
Manual Leveling Joysticks …………………………………… 61
Automatic Leveling Switch …………………………………… 61
Water Injection On/Off Switch (Optional) ……………………… 61
Water Injection Flow Control (Optional) ………………………. 61
Horn Push-button …………………………………………… 62
Depth Indicator Reset Push-button ……………………………. 62
Programmed Drill Control Switch ……………………………… 62
Emergency Stop Push-button (optional) ………………………… 62
Operator’s Display Terminal …………………………………. 63
OPERATOR’S DISPLAY PANEL ……………………………………. 63
Machinery House Controls ……………………………………. 64
Lighting Load Center ……………………………………….. 64
LIGHTING LOAD CENTER ……………………………………….. 64
Controls Located On Low Voltage Start Cabinet …………………. 65
TYPICAL LOW VOLTAGE START CABINET ……………………………. 65
Controls Located On Low Voltage Cabinet ………………………. 65
TYPICAL LOW VOLTAGE CABINET …………………………………. 65
Control Located On Programmable Controller Cabinet …………….. 66
TYPICAL PROGRAMMABLE CONTROL CABINET …………………………. 66
Hoist/Pulldown and Rotary Drive Control CABINETS ………………. 66
TYPICAL HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ……….. 66
Miscellaneous Controls …………………………………….. 67
Portable Remote Propel Station (Optional) ……………………. 67
PORTABLE REMOTE PROPEL STATION ………………………………. 67
Hydraulic Reservoir Remote Fill Control Panel …………………. 68
HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL …………………. 68
Lube Control Panel …………………………………………. 68
LUBE CONTROL PANEL …………………………………………. 68
Prestart Checks ……………………………………………. 69
EXTERNAL Inspection ……………………………………….. 69
Onboard Inspection …………………………………………. 71
Prestart Lubrication ……………………………………….. 73
START-UP ………………………………………………….. 74
Machine Start Up ………………………………………….. 74
Machinery Check ……………………………………………. 75
Break-In of New Components ………………………………….. 75
Rotary Drive unit Break-In ………………………………….. 75
Hoist/Pulldown Gearcase Break-In …………………………….. 75
Electric Motor Break-In …………………………………….. 75
OPERATION ………………………………………………… 76
Propelling ………………………………………………… 76
Definitions ……………………………………………….. 76
PROPEL Procedure …………………………………………… 77
PROPEL CONTROLS – OVERVIEW ………………………………….. 78
STRAIGHT PROPEL ……………………………………………. 79
GRADUAL RIGHT HAND TURN …………………………………….. 79
GRADUAL LEFT HAND TURN ……………………………………… 80
COUNTER-ROTATION LEFT HAND TURN ……………………………… 81
ENSURE GRADUAL TURNS ARE MADE – 15O INCREMENTS ……………….. 81
Towing PROCEDURE …………………………………………… 83
TOWING PROCEDURE …………………………………………… 83
Cable Reel Operation ……………………………………….. 85
CABLE REEL ………………………………………………… 85
Leveling …………………………………………………. 86
…………………………………………………………. 86
LEVELING CONTROLS ………………………………………….. 87
Mast Raising and Lowering …………………………………… 88
Mast Raising ………………………………………………. 88
MAST RAISING/LOWERING CONTROLS ………………………………. 89
Mast Lowering ……………………………………………… 90
MAST CONTROLS TO ADJUST FOR ANGLE DRILLING ……………………. 90
Pulldown Machinery Operation ………………………………… 92
HOIST/PULLDOWN CONTROLS …………………………………….. 92
Auxiliary Winch Operation …………………………………… 93
WINCH OPERATION CONTROLS ……………………………………. 93
Pipe Rack Operation ………………………………………… 94
PIPE RACK OPERATING CONTROLS ………………………………… 94
PIPE RACK OPERATION ………………………………………… 95
Tool Handling ……………………………………………… 97
Pipe Loading and Unloading ………………………………….. 97
Drill Tool String Assembly …………………………………. 99
TOOL STRING ……………………………………………….. 99
STABILIZER INSTALLATION ……………………………………..100
DRILL PIPE INSTALLATION CONTROLS ……………………………..100
Breakout Wrench Operation ……………………………………103
Drill Tool String Disassembly ………………………………..105
Adding Additional Drill Pipe …………………………………107
Removal of Multiple Section Drill Pipe ………………………..108
Angle Drilling ……………………………………………..109
ANGLE DRILLING EQUIPMENT …………………………………….109
PIPE POSITIONER …………………………………………….110
JIB CRANE ………………………………………………….111
Dust Suppression System Operation …………………………….112
WATER INJECTION SYSTEM ………………………………………113
DRILLING …………………………………………………..114
Vertical Drilling …………………………………………..114
CONTROLS UTILIZED WHILE DRILLING ……………………………..114
STARTING The Hole (Collaring) ……………………………….115
Normal Drilling …………………………………………….117
Ending the Hole ……………………………………………118
Ending the Hole (Multiple Pipe Sections) ………………………119
Drilling Difficult Formations ………………………………..119
Unconsolidated Materials …………………………………….120
Wet or Sticky Formations …………………………………….122
Angle Drilling …………………………………………….123
Programmed Drill Control Drilling ……………………………124
PROGRAMMED DRILL CONTROLS UTILIZED ……………………………124
Preparing to Move …………………………………………..125
MACHINE SHUTDOWN ……………………………………………127
Shut Down Procedure …………………………………………127
Short Term Storage ………………………………………….128
Long Term Storage …………………………………………..129
Attended Long Term Storage …………………………………..130
Unattended Long Term Storage …………………………………130
TOOL RECOVERY ………………………………………………131
Drill stability charts ………………………………………195
10390_3.pdf……………………………………………………….. 0
Table of Contents……………………………………………….136
LUBRICATION PRINCIPLES ………………………………………138
Auto Lube Control Panel ……………………………………..139
Auto Lube Reservoir …………………………………………140
Auto Lube Piping ~Mainframe (View #1) …………………………141
Auto Lube Piping ~Mainframe (View #2) …………………………142
Auto Lube Piping ~Crawlers …………………………………..143
Auto Lube Piping ~Mast (View #1) ……………………………..144
Auto Lube Piping ~Mast (View #2) ……………………………..145
LINCOLN TYPE SL-1 LUBRICANT INJECTORS …………………………146
Lubricant Injector Operation …………………………………147
Injector Advantages ………………………………………..148
Troubleshooting …………………………………………….149
Bit Lubricator ……………………………………………..150
FLOWMASTER Pump Servicing ……………………………………151
Pressure CONTROL VALVE ADJUSTMENT …………………………….151
FLOW CONTROL VALVE ADJUSTMENT ………………………………..152
FlowMaster Rotary Driven Hydraulic Pump Schematic ………………152
CRANK CASE OIL ……………………………………………..152
PUMP DISASSEMBLY PROCEDURE …………………………………..153
FlowMaster Rotory Driven Hydraulic Pump Assembly ……………….154
PUMP ASSEMBLY PROCEDURE ……………………………………..155
FlowMaster Rotary Driven Hydraulic Pump Components ……………..156
TROUBLESHOOTING …………………………………………….157
MAST LUBRICATION ~PART 2 …………………………………….159
Lubrication Points ………………………………………….160
GEARCASE AND RESERVOIR CAPACITIES …………………………….160
Lower works lubrication ……………………………………..161
MAIN FRAME LUBRICATION ………………………………………162
MAST LUBRICATION ~PART 1 …………………………………….163
MAST LUBRICATION ~PART 3 …………………………………….164
LUBRICANT CLEANLINESS ……………………………………….165
LUBRICATION BENCHMARKS ………………………………………166
RGL – REGULAR GEAR LUBRICANT …………………………………166
General Requirements for RGL Lubricants ……………………….166
Dragline Specific Data ………………………………………168
Dragline Viscosity and Pour Point Requirements …………………168
Shovel & Drill Specific Data …………………………………168
Shovel / Drill Viscosity and Pour Point Requirements ……………169
ASTM Standard Viscosity / Temperature Chart …………………..170
ACSL – AIR COMPRESSOR (SCREW-TYPE) LUBRICANT …………………..171
MPO – Multipurpose OIL ………………………………………172
RWRL – RUNNING WIRE ROPE LUBRICANT ……………………………173
HYDO – Hydraulic Oil ………………………………………..175
PAO Synthetic Hydraulic Fluid ………………………………..176
Recommended Viscosity vs. OAT Chart …………………………..176
Paraffinic Base Petroleum Hydraulic Fluid ……………………..176
Recommended Viscosity vs. OAT Chart …………………………..177
10390_4.pdf……………………………………………………….. 0
Table of Contents……………………………………………….192
INTRODUCTION ……………………………………………….194
ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM ………………….196
SCHEDULED PREVENTIVE MAINTENANCE PROGRAM ……………………..196
General Safety Considerations ………………………………..197
Maintenance During Machine Operation ………………………….197
Maintenance Precautions ……………………………………..198
PREVENTIVE MAINTENANCE FOR Lubrication ………………………..199
Lubricant CLEANLINESS ……………………………………….200
Frequency of inspection and maintenance ………………………201
MAINTENANCE SCHEDULES ……………………………………….201
DAILY Check Points ………………………………………….202
external inspection …………………………………………202
Onboard Inspection ………………………………………….205
AFTER START-UP INSPECTION …………………………………..209
WEEKLY CHECK points …………………………………………210
ON-BOARD INSPECTION …………………………………………213
Monthly Check Points ………………………………………..215
semi-ANNUAL Check Points …………………………………….217
10390_5.pdf……………………………………………………….. 0
Table of Contents……………………………………………….220
Crawler Belts ………………………………………………226
Lower Works – Overview ………………………………………226
Adjustment …………………………………………………227
Crawler Belt Tension – Checking ………………………………227
Crawler Belt Adjustment – Details …………………………….228
Link Replacement …………………………………………..229
Belt Replacement …………………………………………..230
Crawler Belt Replacement – Details …………………………..230
Lower Rollers ………………………………………………231
Lower Roller – Details ………………………………………231
Repair …………………………………………………….232
Upper Rollers ………………………………………………233
Upper Roller – Details ………………………………………233
Repair …………………………………………………….234
Take-up tumblers ……………………………………………235
Repair …………………………………………………….235
Drive Tumbler ………………………………………………237
Drive Tumbler and Planetary Gearbox Installation ……………….237
Repair …………………………………………………….237
Planetary Gearbox …………………………………………..238
GEARBOX REMOVAL AND INSTALLATION ……………………………..238
Planetary Gearbox Mount Bolt Torque Sequence …………………..239
Checking/Changing Oil ……………………………………….240
Planetary Gearbox Oil Check – Details …………………………240
LUBRICANT SPECIFICATIONS …………………………………….241
Planetary Gearbox Lubrication Specifications …………………..241
Oil Change Intervals ………………………………………..241
Crawler frames ……………………………………………..242
Repair …………………………………………………….242
Crawler Frame Removal/Blocking ……………………………….243
Axles ……………………………………………………..244
Equalizer Axle – Details …………………………………….244
Repair …………………………………………………….244
Rear Axle – Details …………………………………………245
Mainframe ………………………………………………….247
Main Frame – Details ………………………………………..247
Repair …………………………………………………….248
Bit viewing hatch …………………………………………..248
Bit Viewing Hatch – Details ………………………………….248
Mast A-Frame ……………………………………………….249
Repair …………………………………………………….249
Leveling jacks ……………………………………………..250
Leveling Jack – Details …………………………………….250
Repair …………………………………………………….251
Machinery House …………………………………………….254
Repair …………………………………………………….254
Machinery House – Exploded View ………………………………255
House ventilation fan and filter ……………………………..256
Machinery House Ventilation Fan ………………………………256
Walkways and Ladders ………………………………………..257
Retractable Boarding Stairway – Details ……………………….257
Operator’s Cab ……………………………………………..258
Operator’s Cab Location Mounting ……………………………..258
Operator’s Seat …………………………………………….259
Operator’s Seat – Adjustments ………………………………..259
Operator’s Controls …………………………………………259
Operator’s Controls ………………………………………..259
Air Conditioning Unit ……………………………………….260
Operator’s Cab Heating/Air Conditioning Unit …………………..260
Hydraulic pump drive ………………………………………..261
Hydraulic Pump Drive ………………………………………..261
Hydraulic Pump Drive Gearbox – Details ……………………….262
Cable Reel …………………………………………………264
Cable Reel – Details ……………………………………….264
Cable Reel Hydraulics – Details ……………………………..265
Level Wind Drive Adjustment …………………………………266
Hydraulic Adjustments ……………………………………….267
Hydraulic Pump Adjustments …………………………………..267
HYDRAULIC DRIVE START UP INSTRUCTIONS …………………………268
Cable Reel Level Wind – Details ………………………………269
Lubrication ………………………………………………..270
Hydraulic Maintenance ……………………………………….270
Repair …………………………………………………….270
Mast Structure ……………………………………………..271
Repair …………………………………………………….272
Mast Safety Slings ………………………………………….272
Upper Safety Sling …………………………………………272
Repair …………………………………………………….273
Lower Safety Sling – Optional ………………………………..273
Rotary Gearcase …………………………………………….274
Rotary Machinery/Gearcase ……………………………………274
Drive Shaft Adjustment ……………………………………..275
Rotary Machinery Intermediate Shaft …………………………..276
Repair …………………………………………………….277
Remove the upper bearing retainer. ……………………………277
Rotary Machine Driveshaft – Details ………………………..281
Rotary Motor ……………………………………………….284
Rotary Drive Motor – Details …………………………………284
Rotary Coupling ……………………………………………286
Repair …………………………………………………….286
Rotary Shock Coupling ……………………………………….288
Repair …………………………………………………….288
Rotary/Pulldown Guide Frame ………………………………….290
Rotary Pulldown Guide Frame – Details …………………………290
Guide Roller Adjustment ……………………………………..292
Rack Pinion and Upper Guide Roller – Details …………………..292
Lower Guide Rollers – Details ………………………………..293
Repair …………………………………………………….294
COUPLING ALIGNMENT ………………………………………….297
Pulldown Gearcase …………………………………………..299
Pulldown Machinery – Overview ………………………………..299
Repair …………………………………………………….300
Pulldown/Machinery Gearcase and Base ………………………….300
Pulldown/Machinery First Intermediate and Shipper Shaft …………301
Pulldown Machinery Second Intermediate Shaft …………………..302
Pulldown Machinery Input Shaft ……………………………….304
Hoist Brake ………………………………………………..307
Inspection …………………………………………………307
Brake Wear Adjustment ……………………………………….307
Hoist Brake – Details ……………………………………….308
Brake Wear Adjustment ……………………………………….309
Replacement of Friction Discs ………………………………..309
Disassembly of Magnet Body and Armature ……………………….310
Re-assembly of Magnet Body and Armature ……………………….310
PIPE RACKS …………………………………………………311
RH Pipe Rack – Details ………………………………………311
LH Pipe Rack – Details ………………………………………312
Repair …………………………………………………….312
Pipe Rack Variable Equipment …………………………………314
Tool Wrench ………………………………………………..315
Tool Wrench – Details ……………………………………….315
Repair …………………………………………………….316
Breakout Wrench …………………………………………….317
Repair …………………………………………………….317
GENERAL GUIDELINES FOR DISASSEMBLY ……………………………317
Auxiliary Winch …………………………………………….318
Mast Braces ………………………………………………..319
Mast Braces – Details ……………………………………….319
Repair …………………………………………………….320
Adjustment …………………………………………………320
Hydraulic System ……………………………………………321
System Operation ……………………………………………321
Hydraulic Components – Overview ………………………………321
Cylinder Circuit Hydraulic System …………………………….322
Propel Circuit Hydraulic System ………………………………323
GENERAL MAINTENANCE …………………………………………323
Hydraulic System Cleanliness …………………………………323
Oil Requirements ……………………………………………324
Oil and Filter Changes ………………………………………324
Weekly Maintenance Checks ……………………………………325
Oil Reservoir Repairs ……………………………………….325
Leveling Jack Counterbalance Valve Pressure Relieving Procedure ….325
Rear Jacks …………………………………………………326
Front Jack …………………………………………………326
Pre-start Inspection ………………………………………..327
Hydraulic Systems Tests ……………………………………..328
Propel Pump Charge Pressure Check …………………………….328
Control Pressure Check ………………………………………329
Propel Enable Valve and Low Speed Select Check ………………..329
Jack Cylinder Check in Manual Mode ……………………………330
Flow Control Check ………………………………………….331
Jack Cylinder Drift Test …………………………………….333
Brake Release Pressure Check …………………………………333
Propel Brake Emergency Release Check ………………………….334
Propel Pump Main Relief Pressure Check ………………………..334
Crawler Function Check ………………………………………335
Bit Viewing Hatch Check ……………………………………..336
Boarding Stair Check ………………………………………..336
Main Flow Valve Check ……………………………………….336
Breakout Wrench and Tool Wrench Check …………………………336
Dust Curtain Cylinders ………………………………………336
Dust Seal Slider ……………………………………………337
Mast Lock ………………………………………………….337
Mast Brace Lock Cylinders ……………………………………337
A-Frame Lock Cylinders ………………………………………337
Mast Lock Constant Pressure Check …………………………….338
Mast Brace Constant Pressure Check ……………………………338
A-Frame Lock Constant Pressure Check ………………………….338
Mast Raise/Lower ……………………………………………339
Auxiliary Winch …………………………………………….340
Hydraulic Central Lube Drive Pressure Check ……………………341
Window Guard Function Check ………………………………….342
Water Injection Drain Valves Check ……………………………342
Water Injection Pump Function Check …………………………..342
Water Injection Washdown Check ……………………………….344
Check Jacks in Auto Level Mode ……………………………….345
Pipe Rack Position Check …………………………………….346
Pipe Rack Lock and Gate Cylinder Port Relief Setting ……………346
Pipe Thread Lubricator Check …………………………………346
Pipe Positioner Function Check ……………………………….347
Center Guide Function Check plus Constant Pressure Check ………..348
Automatic breakout wrench check ………………………………349
DUST CONTROL ……………………………………………….349
GENERAL MAINTENANCE …………………………………………349
Drilling Platforms and Dust Curtains ………………………….349
Water Injection …………………………………………….350
Operation ………………………………………………….350
Filling Water Tank ………………………………………….350
10390_6.pdf……………………………………………………….. 0
Table of Contents……………………………………………….363
BRAKE HUB INSTALLATION ………………………………………365
Hub Adapter Pre-Heat Advance Requirements Table ………………..366
MOTOR COUPLING INSTALLATION ………………………………….367
Motor Coupling Pre-Heat Advance Requirements Table ……………..368
PARALLEL MISALIGNMENT ……………………………………….369
Checking for Parallel Misalignment ……………………………369
ANGULAR MISALIGNMENT ………………………………………..370
Checking for Angular Misalignment …………………………….370
MISALIGNMENT Examples ……………………………………….371
Parallel Misalignment Example ………………………………..371
Angular Misalignment Example …………………………………371
Combination Misalignment Example ……………………………..371
10390_7.pdf……………………………………………………….. 0
Table of Contents……………………………………………….373
Compressed Air Systems ………………………………………375
AIR COMPRESSOR ……………………………………………..376
Separator Control Components …………………………………377
Air Intake Filter …………………………………………..378
Oil Drain Valve …………………………………………….379
VARIABLE VOLUME Control ……………………………………..379
Separator Maintenance ……………………………………….381
SEPARATOR COVER HARDWARE TIGHTENING PROCEDURE ………………….382
ROTARY SCREW COMPRESSOR ……………………………………..383
Compressor Air End Assembly ………………………………….383
Compressor START-UP …………………………………………385
Compressor SHUTDOWN Modes ……………………………………386
Compressor Failure Fault …………………………………….386
Compressor Cooling Failure Fault ……………………………..386
Compressor Overheat Fault ……………………………………386
Compressor Air Temperature Fault ……………………………..386
THERMOSTATIC CONTROL VALVE …………………………………..387
INTAKE VALVE, Air End ……………………………………….389
AIR END INPUT SHAFT OIL SEAL REPLACEMENT ……………………..393
INLET REGULATING VALVE ………………………………………394
AIR PRESSURE CONTROL VALVE …………………………………..395
DISCHARGE AIR TEMPERATURE GAUGE ………………………………395
SAFETY RELIEF VALVE …………………………………………396
SOLENOID BLOWDOWN VALVE ……………………………………..396
COMPRESSOR OIL STRAINER & FILTERS …………………………….396
10390_8.pdf……………………………………………………….. 0
Table of Contents……………………………………………….399
AIR CONDITIONING UNIT ……………………………………….401
DESCRIPTION ……………………………………………….401
Overview …………………………………………………..401
Evaporator …………………………………………………401
Condenser ………………………………………………….402
Specifications ……………………………………………..402
House Fans …………………………………………………403
Inspection …………………………………………………403
Lubrication ………………………………………………..404
10390_9.pdf……………………………………………………….. 0
Table of Contents……………………………………………….405
Capscrew (Bolt) Grade ……………………………………….407
BOLT TIGHTENING …………………………………………….408
TORQUE WRENCH METHOD ………………………………………..408
Table 1 – Lubricated or Plated Threads or with Hardened Washers ….408
Table 2 – Dry Threads ……………………………………….408
TURN-OF-NUT METHOD ………………………………………….409
Table of Snug Tight Torque Values …………………………….409
WIRE LOCKING CAPSCREWS ………………………………………410
Patterns for Wirelocking Capscrews ……………………………410
GEAR INSPECTION …………………………………………….411
Gear Tooth Surface Failures …………………………………412
AEROQUIP ORS CONNECTIONS …………………………………….413
ORS Connection Assembly ……………………………………..413
Seals ……………………………………………………..414
SEAL INSTALLATION …………………………………………..414
Gearcase Sealing ……………………………………………416
MAINTENANCE WELDING …………………………………………417
WELDING ELECTRODES ………………………………………….418
REPAIR WELDING OF CRACKS …………………………………….419
Joint Preparation for Repair of Cracks ………………………..419
PREHEAT ……………………………………………………420
WELDING TECHNIQUE …………………………………………..420
REPAIR WELDING OF BROKEN PARTS ……………………………….421
WELDING AND CUTTING EQUIPMENT ………………………………..422
STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT ……………..422
WIRE ROPE Care and Maintenance ……………………………….424
Storage …………………………………………………..424
Checking Diameter ………………………………………….424
Correct Method for Checking Wire Rope Diameter …………………424
Handling Wire Rope …………………………………………425
Improper Methods for Uncoiling Wire Rope ………………………426
End Preparations/Terminations ………………………………..427
Wire Rope Clips …………………………………………….428
Wire Rope Clip Application ………………………………….428
Wedge Sockets ……………………………………………..430
Inspection of Sheaves and Drums ……………………………..431
Examples of Sheave Groove Conditions ………………………….431
Groove Gauge for New or Re-Worked Sheaves ……………………..431
Inspecting for Worn Sheave …………………………………..432
Breaking In a New Wire Rope …………………………………432
Inspection Data …………………………………………….433
Guideline to Inspections and Reports …………………………434
Wire Rope Stretch vs Rope Life ……………………………….436
Examples of Broken Wires …………………………………….439
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