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CAT BUCYRUS 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL SN 141239 – PDF DOWNLOAD
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CAT BUCYRUS 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL SN 141239 – PDF DOWNLOAD
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Description
CAT BUCYRUS 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL SN 141239 – PDF DOWNLOAD
FILE DETAILS:
CAT BUCYRUS 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL SN 141239 – PDF DOWNLOAD
Language : English
Pages : 436
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT BUCYRUS 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL SN 141239 – PDF DOWNLOAD
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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT BUCYRUS 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL SN 141239 – PDF DOWNLOAD
10483_1.pdf................................................................. 0 10483_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 PROPEL MACHINERY ............................................... 21 MAIN FRAME AND DECKS ........................................... 22 Machinery House ................................................ 23 MAIN AIR SYSTEMS ............................................... 24 Air Compressor ................................................. 24 HYDRAULIC SYSTEM ............................................... 25 OPERATOR'S CAB ................................................. 26 MAST ........................................................... 26 Mast/Machinery ................................................. 27 Rotary Gearcase ................................................ 28 Pulldown Gearcase .............................................. 29 Drill Tool String Assembly ..................................... 30 Breakout Wrench ................................................ 31 Cable Reel .................................................... 31 TYPICAL MACHINE Specifications ................................. 33 General Estimated COMPONENT WEIGHTS ............................ 35 10483_2.pdf................................................................. 0 Table of Contents....................................................... 40 GENERAL INFORMATION ................................................ 44 OPERATION NEAR ELECTRICAL TRANSMISSION LINES ...................... 44 CONTROLS - LOCATION AND FUNCTION .................................. 45 OPERATOR'S CONTROL console ......................................... 46 OPERATOR'S CONTROL CONSOLE - OVERVIEW .............................. 46 Main Control Panel ................................................ 47 MAIN CONTROL PANEL - OVERVIEW ...................................... 47 Hoist/Pulldown Rheostat ............................................ 47 Rotary Rheostat .................................................... 48 Drill/Propel Controls ON and OFF Push-button ....................... 48 Hoist/Pulldown Speed Selector Switch ............................... 49 Rotary Speed Selector Switch ....................................... 49 Hoist Brake Switch ................................................. 50 Pipe Rack Selector Switch .......................................... 50 Pipe Rack Joystick (Left Crawler Propel) ........................... 50 Winch/Mast Selector Switch ......................................... 51 Mast/Winch Joystick (Right Crawler Propel) ......................... 51 Tool Wrench Switch ................................................. 52 Dust Curtain Switch ................................................ 52 Bit View Hatch Switch .............................................. 52 Propel Control Panel ............................................... 53 PROPEL CONTROL PANEL - OVERVIEW .................................... 53 Emergency Stop Push-button (Optional) .............................. 53 Propel Speed Selector Switch ....................................... 54 Compressor Stop Push-button ........................................ 54 Compressor Vent/Drill Switch ....................................... 54 Heater/Vent/Air Conditioner Controls ............................... 54 Operating Mode Selector Switch ..................................... 54 Propel Joysticks ................................................... 55 Selector Switch Panel .............................................. 55 SELECTOR SWITCH PANEL - OVERVIEW ................................... 55 Breakout Wrench Switch ............................................. 56 Pipe Positioner Switch (Optional) .................................. 56 Dust Seal Switch (Optional) ........................................ 56 A-Frame Lock Switch (Optional) ..................................... 56 Mast Brace Lock Switch ............................................. 56 Mast Lock Switch ................................................... 57 Boarding Stairs Switch ............................................. 57 Pedestal Heater Switch (Optional) .................................. 57 Fire Suppression System Indicators (Optional) ...................... 57 RADIO (Optional) ................................................... 57 Leveling Control Panel ............................................. 58 LEVELING CONTROL PANEL ............................................. 58 Manual Leveling Joysticks .......................................... 59 Automatic Leveling Switch .......................................... 59 Water Injection On/Off Switch (Optional) ........................... 59 Water Injection Flow Control (Optional) ............................ 59 Horn Push-button ................................................... 60 Depth Indicator Reset Push-button .................................. 60 Programmed Drill Control Switch .................................... 60 Emergency Stop Push-button (optional) .............................. 60 Operator's Display Terminal ........................................ 61 OPERATOR'S DISPLAY PANEL ........................................... 61 Machinery House Controls ........................................... 62 Lighting Load Center ............................................... 62 LIGHTING LOAD CENTER ............................................... 62 Controls Located On Low Voltage Start Cabinet ...................... 63 TYPICAL LOW VOLTAGE START CABINET .................................. 63 Controls Located On Low Voltage Cabinet ............................ 63 TYPICAL LOW VOLTAGE CABINET ........................................ 63 Control Located On Programmable Controller Cabinet ................. 64 TYPICAL PROGRAMMABLE CONTROL CABINET ............................... 64 Hoist/Pulldown and Rotary Drive Control CABINETS ................... 64 TYPICAL HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ........... 64 Hydraulic Reservoir Remote Fill Control Panel ...................... 65 HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL ...................... 65 Lube Control Panel ................................................. 65 LUBE CONTROL PANEL ................................................. 65 Prestart Checks .................................................... 66 EXTERNAL Inspection ............................................... 66 Onboard Inspection ................................................. 68 Prestart Lubrication ............................................... 70 START-UP ........................................................... 71 Machine Start Up .................................................. 71 Machinery Check .................................................... 72 Break-In of New Components ......................................... 72 Rotary Drive unit Break-In ......................................... 72 Hoist/Pulldown Gearcase Break-In ................................... 72 Electric Motor Break-In ............................................ 72 OPERATION ......................................................... 73 Propelling ......................................................... 73 Definitions ........................................................ 73 PROPEL Procedure ................................................... 74 PROPEL CONTROLS - OVERVIEW ......................................... 75 STRAIGHT PROPEL .................................................... 76 GRADUAL RIGHT HAND TURN ............................................ 76 GRADUAL LEFT HAND TURN ............................................. 77 COUNTER-ROTATION LEFT HAND TURN .................................... 78 ENSURE GRADUAL TURNS ARE MADE - 15O INCREMENTS .................... 78 Towing PROCEDURE ................................................... 80 TOWING PROCEDURE ................................................... 80 Cable Reel Operation ............................................... 82 CABLE REEL ......................................................... 82 Leveling .......................................................... 83 LEVELING CONTROLS .................................................. 84 Mast Raising and Lowering .......................................... 85 Mast Raising ....................................................... 85 MAST RAISING/LOWERING CONTROLS ..................................... 86 Mast Lowering ...................................................... 87 MAST CONTROLS TO ADJUST FOR ANGLE DRILLING ......................... 87 Pulldown Machinery Operation ....................................... 89 HOIST/PULLDOWN CONTROLS ............................................ 89 Auxiliary Winch Operation .......................................... 90 WINCH OPERATION CONTROLS ........................................... 90 Pipe Rack Operation ................................................ 91 PIPE RACK OPERATING CONTROLS ....................................... 91 PIPE RACK OPERATION ................................................ 92 Tool Handling ...................................................... 94 Pipe Loading and Unloading ......................................... 94 Drill Tool String Assembly ........................................ 96 TOOL STRING ........................................................ 96 STABILIZER INSTALLATION ............................................ 97 DRILL PIPE INSTALLATION CONTROLS ................................... 97 Breakout Wrench Operation ..........................................100 Drill Tool String Disassembly ......................................102 Adding Additional Drill Pipe .......................................104 Removal of Multiple Section Drill Pipe .............................105 Dust Suppression System Operation ..................................106 WATER INJECTION SYSTEM .............................................107 DRILLING ...........................................................108 Vertical Drilling ..................................................108 CONTROLS UTILIZED WHILE DRILLING ...................................108 STARTING The Hole (Collaring) .....................................109 Normal Drilling ....................................................111 Ending the Hole ...................................................112 Ending the Hole (Multiple Pipe Sections) ...........................113 Drilling Difficult Formations ......................................113 Unconsolidated Materials ...........................................114 Wet or Sticky Formations ...........................................116 Programmed Drill Control Drilling .................................118 PROGRAMMED DRILL CONTROLS UTILIZED .................................118 Preparing to Move ..................................................119 MACHINE SHUTDOWN ...................................................121 Shut Down Procedure ................................................121 Short Term Storage .................................................122 Long Term Storage ..................................................123 Attended Long Term Storage .........................................124 Unattended Long Term Storage .......................................124 TOOL RECOVERY ......................................................125 Drill stability charts .............................................127 10483_3.pdf................................................................. 0 Table of Contents.......................................................130 LUBRICATION PRINCIPLES .............................................132 Auto Lube Control Panel ............................................133 Auto Lube Reservoir ................................................134 Auto Lube Piping ~Mainframe (View #1) ..............................135 Auto Lube Piping ~Mainframe (View #2) ..............................136 Auto Lube Piping ~Crawlers .........................................137 Auto Lube Piping ~Mast (View #1) ...................................138 Auto Lube Piping ~Mast (View #2) ...................................139 LINCOLN TYPE SL-1 LUBRICANT INJECTORS ..............................140 Lubricant Injector Operation .......................................141 Injector Advantages ...............................................142 Troubleshooting ....................................................143 Bit Lubricator .....................................................144 FLOWMASTER Pump Servicing ..........................................145 Pressure CONTROL VALVE ADJUSTMENT ..................................145 FLOW CONTROL VALVE ADJUSTMENT ......................................146 FlowMaster Rotary Driven Hydraulic Pump Schematic ..................146 CRANK CASE OIL .....................................................146 PUMP DISASSEMBLY PROCEDURE .........................................147 FlowMaster Rotory Driven Hydraulic Pump Assembly ...................148 PUMP ASSEMBLY PROCEDURE ............................................149 FlowMaster Rotary Driven Hydraulic Pump Components .................150 TROUBLESHOOTING ....................................................151 Lube Pump Hydraulic Schematic ......................................152 Lubrication Points .................................................153 GEARCASE AND RESERVOIR CAPACITIES ..................................153 Lower works lubrication ............................................154 MAIN FRAME LUBRICATION .............................................155 MAST LUBRICATION ~PART 1 ...........................................156 MAST LUBRICATION ~PART 2 ...........................................157 MAST LUBRICATION ~PART 3 ...........................................158 LUBRICANT CLEANLINESS ..............................................159 LUBRICANT SELECTION ................................................160 ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT .......................161 MPO - Multipurpose OIL .............................................162 RWRL - RUNNING WIRE ROPE LUBRICANT .................................163 HYDO - Hydraulic Oil ...............................................165 PAO Synthetic Hydraulic Fluid ......................................166 Recommended Viscosity vs. OAT Chart ................................166 Paraffinic Base Petroleum Hydraulic Fluid ..........................166 Recommended Viscosity vs. OAT Chart ................................167 10483_4.pdf................................................................. 0 Table of Contents.......................................................188 INTRODUCTION .......................................................190 ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM ......................192 SCHEDULED PREVENTIVE MAINTENANCE PROGRAM ..........................192 General Safety Considerations ......................................193 Maintenance During Machine Operation ...............................193 Maintenance Precautions ............................................194 PREVENTIVE MAINTENANCE FOR Lubrication .............................195 Lubricant CLEANLINESS ..............................................196 Frequency of inspection and maintenance ...........................197 MAINTENANCE SCHEDULES ..............................................197 DAILY Check Points .................................................198 external inspection ................................................198 Onboard Inspection .................................................201 AFTER START-UP INSPECTION .........................................205 WEEKLY CHECK points ................................................206 ON-BOARD INSPECTION ................................................209 Monthly Check Points ...............................................211 semi-ANNUAL Check Points ...........................................213 10483_5.pdf................................................................. 0 Table of Contents.......................................................216 Crawler Belts ......................................................222 Lower Works - Overview .............................................222 Adjustment .........................................................223 Crawler Belt Tension - Checking ....................................223 Crawler Belt Adjustment - Details ..................................224 Link Replacement ..................................................225 Belt Replacement ..................................................226 Crawler Belt Replacement - Details ................................226 Lower Rollers ......................................................227 Lower Roller - Details .............................................227 Repair .............................................................228 Upper Rollers ......................................................229 Upper Roller - Details .............................................229 Repair .............................................................230 Take-up tumblers ...................................................231 Repair .............................................................231 Drive Tumbler ......................................................233 Drive Tumbler and Planetary Gearbox Installation ...................233 Repair .............................................................233 Planetary Gearbox ..................................................234 GEARBOX REMOVAL AND INSTALLATION ...................................234 Planetary Gearbox Mount Bolt Torque Sequence .......................235 Checking/Changing Oil ..............................................236 Planetary Gearbox Oil Check - Details ..............................236 LUBRICANT SPECIFICATIONS ...........................................237 Planetary Gearbox Lubrication Specifications .......................237 Oil Change Intervals ...............................................237 Crawler frames .....................................................238 Repair .............................................................238 Crawler Frame Removal/Blocking .....................................239 Axles ..............................................................240 Equalizer Axle - Details ...........................................240 Repair .............................................................240 Rear Axle - Details ................................................241 Mainframe ..........................................................243 Main Frame - Details ...............................................243 Repair .............................................................244 Bit viewing hatch ..................................................244 Bit Viewing Hatch - Details ........................................244 Mast A-Frame .......................................................245 Repair .............................................................245 Leveling jacks .....................................................246 Leveling Jack - Details ...........................................246 Repair .............................................................247 Machinery House ....................................................250 Repair .............................................................250 Machinery House - Exploded View ....................................251 House ventilation fan and filter ...................................252 Machinery House Ventilation Fan ....................................252 Walkways and Ladders ...............................................253 Retractable Boarding Stairway - Details ............................253 Operator's Cab .....................................................254 Operator's Cab Location Mounting ...................................254 Operator's Seat ....................................................255 Operator's Seat - Adjustments ......................................255 Operator's Controls ................................................255 Operator's Controls ...............................................255 Air Conditioning Unit ..............................................256 Operator's Cab Heating/Air Conditioning Unit .......................256 Hydraulic pump drive ...............................................257 Hydraulic Pump Drive ...............................................257 Hydraulic Pump Drive Gearbox - Details ............................258 Cable Reel .........................................................260 Cable Reel - Details ..............................................260 Cable Reel Hydraulics - Details ...................................261 Level Wind Drive Adjustment .......................................262 Hydraulic Adjustments ..............................................263 Hydraulic Pump Adjustments .........................................263 HYDRAULIC DRIVE START UP INSTRUCTIONS ..............................264 Cable Reel Level Wind - Details ....................................265 Lubrication ........................................................266 Hydraulic Maintenance ..............................................266 Repair .............................................................266 Mast Structure .....................................................267 Repair .............................................................268 Mast Safety Slings .................................................268 Upper Safety Sling ................................................268 Repair .............................................................269 Lower Safety Sling - Optional ......................................269 Rotary Gearcase ....................................................270 Rotary Machinery/Gearcase ..........................................270 Drive Shaft Adjustment ............................................271 Rotary Machinery Intermediate Shaft ................................272 Repair .............................................................273 Remove the upper bearing retainer. .................................273 Rotary Machine Driveshaft - Details .............................277 Rotary Motor .......................................................280 Rotary Drive Motor - Details .......................................280 Rotary Coupling ...................................................282 Repair .............................................................282 Rotary Shock Coupling ..............................................284 Repair .............................................................284 Rotary/Pulldown Guide Frame ........................................286 Rotary Pulldown Guide Frame - Details ..............................286 Guide Roller Adjustment ............................................288 Rack Pinion and Upper Guide Roller - Details .......................288 Lower Guide Rollers - Details ......................................289 Repair .............................................................290 COUPLING ALIGNMENT .................................................293 Pulldown Gearcase ..................................................295 Pulldown Machinery - Overview ......................................295 Repair .............................................................296 Pulldown/Machinery Gearcase and Base ...............................296 Pulldown/Machinery First Intermediate and Shipper Shaft ............297 Pulldown Machinery Second Intermediate Shaft .......................298 Pulldown Machinery Input Shaft .....................................300 Hoist Brake ........................................................303 Inspection .........................................................303 Brake Wear Adjustment ..............................................303 Hoist Brake - Details ..............................................304 Brake Wear Adjustment ..............................................305 Replacement of Friction Discs ......................................305 Disassembly of Magnet Body and Armature ............................306 Re-assembly of Magnet Body and Armature ............................306 PIPE RACKS .........................................................307 RH Pipe Rack - Details .............................................307 LH Pipe Rack - Details .............................................308 Repair .............................................................308 Pipe Rack Variable Equipment .......................................310 Tool Wrench ........................................................311 Tool Wrench - Details ..............................................311 Repair .............................................................312 Breakout Wrench ....................................................313 Repair .............................................................313 GENERAL GUIDELINES FOR DISASSEMBLY .................................313 Auxiliary Winch ....................................................314 Mast Braces ........................................................315 Mast Braces - Details ..............................................315 Repair .............................................................316 Adjustment .........................................................316 Hydraulic System ...................................................317 System Operation ...................................................317 Hydraulic Components - Overview ....................................317 Cylinder Circuit Hydraulic System ..................................318 Propel Circuit Hydraulic System ....................................319 GENERAL MAINTENANCE ................................................319 Hydraulic System Cleanliness .......................................319 Oil Requirements ...................................................320 Oil and Filter Changes .............................................320 Weekly Maintenance Checks ..........................................321 Oil Reservoir Repairs ..............................................321 Leveling Jack Counterbalance Valve Pressure Relieving Procedure ....321 Rear Jacks .........................................................322 Front Jack .........................................................322 Pre-start Inspection ...............................................323 Hydraulic Systems Tests ............................................324 Propel Pump Charge Pressure Check ..................................324 Control Pressure Check .............................................325 Propel Enable Valve and Low Speed Select Check ....................325 Jack Cylinder Check in Manual Mode .................................326 Flow Control Check .................................................327 Jack Cylinder Drift Test ...........................................329 Brake Release Pressure Check .......................................329 Propel Brake Emergency Release Check ...............................330 Propel Pump Main Relief Pressure Check .............................330 Crawler Function Check .............................................331 Bit Viewing Hatch Check ............................................332 Boarding Stair Check ...............................................332 Main Flow Valve Check ..............................................332 Breakout Wrench and Tool Wrench Check ..............................332 Dust Curtain Cylinders .............................................332 Dust Seal Slider ...................................................333 Mast Lock ..........................................................333 Mast Brace Lock Cylinders ..........................................333 A-Frame Lock Cylinders .............................................333 Mast Lock Constant Pressure Check ..................................334 Mast Brace Constant Pressure Check .................................334 A-Frame Lock Constant Pressure Check ...............................334 Mast Raise/Lower ...................................................335 Auxiliary Winch ....................................................336 Hydraulic Central Lube Drive Pressure Check ........................337 Window Guard Function Check ........................................338 Water Injection Drain Valves Check .................................338 Water Injection Pump Function Check ................................338 Water Injection Washdown Check .....................................340 Check Jacks in Auto Level Mode .....................................341 Pipe Rack Position Check ...........................................342 Pipe Rack Lock and Gate Cylinder Port Relief Setting ...............342 Pipe Thread Lubricator Check .......................................342 Pipe Positioner Function Check .....................................343 Center Guide Function Check plus Constant Pressure Check ...........344 Automatic breakout wrench check ....................................345 DUST CONTROL .......................................................345 GENERAL MAINTENANCE ................................................345 Drilling Platforms and Dust Curtains ...............................345 Water Injection ....................................................346 Operation ..........................................................346 Filling Water Tank .................................................346 Table of Contents.......................................................216 Crawler Belts ......................................................221 Lower Works - Overview .............................................221 Adjustment .........................................................222 Crawler Belt Tension - Checking ....................................222 Crawler Belt Adjustment - Details ..................................223 Link Replacement ..................................................224 Belt Replacement ..................................................225 Crawler Belt Replacement - Details ................................225 Lower Rollers ......................................................226 Lower Roller - Details .............................................226 Repair .............................................................227 Upper Rollers ......................................................228 Upper Roller - Details .............................................228 Repair .............................................................228 Take-up tumblers ...................................................230 Repair .............................................................230 Drive Tumbler ......................................................232 Drive Tumbler and Planetary Gearbox Installation ...................232 Repair .............................................................232 Planetary Gearbox ..................................................233 GEARBOX REMOVAL AND INSTALLATION ...................................233 Planetary Gearbox Mount Bolt Torque Sequence .......................234 Checking/Changing Oil ..............................................235 Planetary Gearbox Oil Check - Details ..............................235 LUBRICANT SPECIFICATIONS ...........................................236 Planetary Gearbox Lubrication Specifications .......................236 Oil Change Intervals ...............................................236 Crawler frames .....................................................237 Repair .............................................................237 Crawler Frame Removal/Blocking .....................................238 Axles ..............................................................239 Equalizer Axle - Details ...........................................239 Repair .............................................................239 Rear Axle - Details ................................................240 Mainframe ..........................................................242 Main Frame - Details ...............................................242 Repair .............................................................243 Bit viewing hatch ..................................................243 Bit Viewing Hatch - Details ........................................243 Mast A-Frame .......................................................244 10483_6.pdf................................................................. 0 Table of Contents.......................................................359 BRAKE HUB INSTALLATION .............................................361 Hub Adapter Pre-Heat Advance Requirements Table ....................362 MOTOR COUPLING INSTALLATION ........................................363 Motor Coupling Pre-Heat Advance Requirements Table .................364 PARALLEL MISALIGNMENT ..............................................365 Checking for Parallel Misalignment .................................365 ANGULAR MISALIGNMENT ...............................................366 Checking for Angular Misalignment ..................................366 MISALIGNMENT Examples ..............................................367 Parallel Misalignment Example ......................................367 Angular Misalignment Example .......................................367 Combination Misalignment Example ...................................367 10483_7.pdf................................................................. 0 Table of Contents.......................................................369 Compressed Air Systems .............................................371 AIR COMPRESSOR .....................................................372 Separator Control Components .......................................373 Air Intake Filter ..................................................374 Oil Drain Valve ....................................................375 VARIABLE VOLUME Control ............................................375 Separator Maintenance ..............................................377 SEPARATOR COVER HARDWARE TIGHTENING PROCEDURE ......................378 ROTARY SCREW COMPRESSOR ............................................379 Compressor Air End Assembly ........................................379 Compressor START-UP ................................................381 Compressor SHUTDOWN Modes ..........................................382 Compressor Failure Fault ...........................................382 Compressor Cooling Failure Fault ...................................382 Compressor Overheat Fault ..........................................382 Compressor Air Temperature Fault ...................................382 THERMOSTATIC CONTROL VALVE .........................................383 INTAKE VALVE, Air End ..............................................385 AIR END INPUT SHAFT OIL SEAL REPLACEMENT ..........................389 INLET REGULATING VALVE .............................................390 AIR PRESSURE CONTROL VALVE .........................................391 DISCHARGE AIR TEMPERATURE GAUGE ....................................391 SAFETY RELIEF VALVE ................................................392 SOLENOID BLOWDOWN VALVE ............................................392 COMPRESSOR OIL STRAINER & FILTERS ..................................392 10483_8.pdf................................................................. 0 Table of Contents.......................................................395 AIR CONDITIONING UNIT ..............................................397 DESCRIPTION .......................................................397 Overview ...........................................................397 Evaporator .........................................................397 Condenser ..........................................................398 Specifications .....................................................398 House Fans .........................................................399 Inspection .........................................................399 Lubrication ........................................................400 10483_9.pdf................................................................. 0 Table of Contents.......................................................401 Capscrew (Bolt) Grade ..............................................403 BOLT TIGHTENING ....................................................404 TORQUE WRENCH METHOD ...............................................404 Table 1 - Lubricated or Plated Threads or with Hardened Washers ....404 Table 2 - Dry Threads ..............................................404 TURN-OF-NUT METHOD .................................................405 Table of Snug Tight Torque Values ..................................405 WIRE LOCKING CAPSCREWS .............................................406 Patterns for Wirelocking Capscrews .................................406 GEAR INSPECTION ....................................................407 Gear Tooth Surface Failures .......................................408 AEROQUIP ORS CONNECTIONS ...........................................409 ORS Connection Assembly ............................................409 Seals ..............................................................410 SEAL INSTALLATION ..................................................410 Gearcase Sealing ...................................................412 MAINTENANCE WELDING ................................................413 WELDING ELECTRODES .................................................414 REPAIR WELDING OF CRACKS ...........................................415 Joint Preparation for Repair of Cracks .............................415 PREHEAT ............................................................416 WELDING TECHNIQUE ..................................................416 REPAIR WELDING OF BROKEN PARTS .....................................417 WELDING AND CUTTING EQUIPMENT ......................................418 STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT .................418 WIRE ROPE Care and Maintenance .....................................420 Storage ...........................................................420 Checking Diameter .................................................420 Correct Method for Checking Wire Rope Diameter .....................420 Handling Wire Rope ................................................421 Improper Methods for Uncoiling Wire Rope ...........................422 End Preparations/Terminations ......................................423 Wire Rope Clips ....................................................424 Wire Rope Clip Application ........................................424 Wedge Sockets .....................................................426 Inspection of Sheaves and Drums ...................................427 Examples of Sheave Groove Conditions ...............................427 Groove Gauge for New or Re-Worked Sheaves ..........................427 Inspecting for Worn Sheave .........................................428 Breaking In a New Wire Rope .......................................428 Inspection Data ....................................................429 Guideline to Inspections and Reports ..............................430 Wire Rope Stretch vs Rope Life .....................................432 Examples of Broken Wires ...........................................435
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