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CAT Bucyrus 49HR Blast Hole Drill Maintenance & Operation Manual SN 141216 – PDF DOWNLOAD
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CAT Bucyrus 49HR Blast Hole Drill Maintenance & Operation Manual SN 141216 – PDF DOWNLOAD
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Description
CAT Bucyrus 49HR Blast Hole Drill Maintenance & Operation Manual SN 141216 – PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus 49HR Blast Hole Drill Maintenance & Operation Manual SN 141216 – PDF DOWNLOAD
Language : English
Pages : 442
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT Bucyrus 49HR Blast Hole Drill Maintenance & Operation Manual SN 141216 – 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.
TABLE OF CONTENTS:
CAT Bucyrus 49HR Blast Hole Drill Maintenance & Operation Manual SN 141216 – PDF DOWNLOAD
10438_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 10438_2.pdf................................................................. 0 Table of Contents....................................................... 0 GENERAL INFORMATION ................................................ 0 OPERATION NEAR ELECTRICAL TRANSMISSION LINES ...................... 0 CONTROLS - LOCATION AND FUNCTION .................................. 0 OPERATOR'S CONTROL console ......................................... 0 OPERATOR'S CONTROL CONSOLE - OVERVIEW .............................. 0 Main Control Panel ................................................ 0 MAIN CONTROL PANEL - OVERVIEW ...................................... 0 Hoist/Pulldown Rheostat ............................................ 0 Rotary Rheostat .................................................... 0 Drill/Propel Controls ON and OFF Push-button ....................... 0 Hoist/Pulldown Speed Selector Switch ............................... 0 Rotary Speed Selector Switch ....................................... 0 Hoist Brake Switch ................................................. 0 Pipe Rack Selector Switch .......................................... 0 Pipe Rack Joystick (Left Crawler Propel) ........................... 0 Winch/Mast Selector Switch ......................................... 0 Mast/Winch Joystick (Right Crawler Propel) ......................... 0 Tool Wrench Switch ................................................. 0 Dust Curtain Switch ................................................ 0 Bit View Hatch Switch .............................................. 0 Propel Control Panel ............................................... 0 PROPEL CONTROL PANEL - OVERVIEW .................................... 0 Emergency Stop Push-button (Optional) .............................. 0 Propel Speed Selector Switch ....................................... 0 Compressor Stop Push-button ........................................ 0 Compressor Vent/Drill Switch ....................................... 0 Heater/Vent/Air Conditioner Controls ............................... 0 Operating Mode Selector Switch ..................................... 0 Propel Joysticks ................................................... 0 Selector Switch Panel .............................................. 0 SELECTOR SWITCH PANEL - OVERVIEW ................................... 0 Breakout Wrench Switch ............................................. 0 Pipe Positioner Switch (Optional) .................................. 0 Dust Seal Switch (Optional) ........................................ 0 A-Frame Lock Switch (Optional) ..................................... 0 Mast Brace Lock Switch ............................................. 0 Mast Lock Switch ................................................... 0 Boarding Stairs Switch ............................................. 0 Pedestal Heater Switch (Optional) .................................. 0 Fire Suppression System Indicators (Optional) ...................... 0 RADIO (Optional) ................................................... 0 Leveling Control Panel ............................................. 0 LEVELING CONTROL PANEL ............................................. 0 Manual Leveling Joysticks .......................................... 0 Automatic Leveling Switch .......................................... 0 Water Injection On/Off Switch (Optional) ........................... 0 Water Injection Flow Control (Optional) ............................ 0 Horn Push-button ................................................... 0 Depth Indicator Reset Push-button .................................. 0 Programmed Drill Control Switch .................................... 0 Emergency Stop Push-button (optional) .............................. 0 Operator's Display Terminal ........................................ 0 OPERATOR'S DISPLAY PANEL ........................................... 0 Machinery House Controls ........................................... 0 Lighting Load Center ............................................... 0 LIGHTING LOAD CENTER ............................................... 0 Controls Located On Low Voltage Start Cabinet ...................... 0 TYPICAL LOW VOLTAGE START CABINET .................................. 0 Controls Located On Low Voltage Cabinet ............................ 0 TYPICAL LOW VOLTAGE CABINET ........................................ 0 Control Located On Programmable Controller Cabinet ................. 0 TYPICAL PROGRAMMABLE CONTROL CABINET ............................... 0 Hoist/Pulldown and Rotary Drive Control CABINETS ................... 0 TYPICAL HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ........... 0 Miscellaneous Controls ............................................ 0 Portable Remote Propel Station (Optional) ......................... 0 PORTABLE REMOTE PROPEL STATION ..................................... 0 Hydraulic Reservoir Remote Fill Control Panel ...................... 0 HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL ...................... 0 Lube Control Panel ................................................. 0 LUBE CONTROL PANEL ................................................. 0 Prestart Checks .................................................... 0 EXTERNAL Inspection ............................................... 0 Onboard Inspection ................................................. 0 Prestart Lubrication ............................................... 0 START-UP ........................................................... 0 Machine Start Up .................................................. 0 Machinery Check .................................................... 0 Break-In of New Components ......................................... 0 Rotary Drive unit Break-In ......................................... 0 Hoist/Pulldown Gearcase Break-In ................................... 0 Electric Motor Break-In ............................................ 0 OPERATION ......................................................... 0 Propelling ......................................................... 0 Definitions ........................................................ 0 PROPEL Procedure ................................................... 0 PROPEL CONTROLS - OVERVIEW ......................................... 0 STRAIGHT PROPEL .................................................... 0 GRADUAL RIGHT HAND TURN ............................................ 0 GRADUAL LEFT HAND TURN ............................................. 0 COUNTER-ROTATION LEFT HAND TURN .................................... 0 ENSURE GRADUAL TURNS ARE MADE - 15O INCREMENTS .................... 0 Towing PROCEDURE ................................................... 0 TOWING PROCEDURE ................................................... 0 Cable Reel Operation ............................................... 0 CABLE REEL ......................................................... 0 Leveling .......................................................... 0 LEVELING CONTROLS .................................................. 0 Mast Raising and Lowering .......................................... 0 Mast Raising ....................................................... 0 MAST RAISING/LOWERING CONTROLS ..................................... 0 Mast Lowering ...................................................... 0 MAST CONTROLS TO ADJUST FOR ANGLE DRILLING ......................... 0 Pulldown Machinery Operation ....................................... 0 HOIST/PULLDOWN CONTROLS ............................................ 0 Auxiliary Winch Operation .......................................... 0 WINCH OPERATION CONTROLS ........................................... 0 Pipe Rack Operation ................................................ 0 PIPE RACK OPERATING CONTROLS ....................................... 0 PIPE RACK OPERATION ................................................ 0 Tool Handling ...................................................... 0 Pipe Loading and Unloading ......................................... 0 Drill Tool String Assembly ........................................ 0 TOOL STRING ........................................................ 0 STABILIZER INSTALLATION ............................................ 0 DRILL PIPE INSTALLATION CONTROLS ................................... 0 Breakout Wrench Operation .......................................... 0 Drill Tool String Disassembly ...................................... 0 Adding Additional Drill Pipe ....................................... 0 Removal of Multiple Section Drill Pipe ............................. 0 Angle Drilling ..................................................... 0 ANGLE DRILLING EQUIPMENT ........................................... 0 PIPE POSITIONER .................................................... 0 JIB CRANE .......................................................... 0 Dust Suppression System Operation .................................. 0 WATER INJECTION SYSTEM ............................................. 0 DRILLING ........................................................... 0 Vertical Drilling .................................................. 0 CONTROLS UTILIZED WHILE DRILLING ................................... 0 STARTING The Hole (Collaring) ..................................... 0 Normal Drilling .................................................... 0 Ending the Hole ................................................... 0 Ending the Hole (Multiple Pipe Sections) ........................... 0 Drilling Difficult Formations ...................................... 0 Unconsolidated Materials ........................................... 0 Wet or Sticky Formations ........................................... 0 Angle Drilling .................................................... 0 Programmed Drill Control Drilling ................................. 0 PROGRAMMED DRILL CONTROLS UTILIZED ................................. 0 Preparing to Move .................................................. 0 MACHINE SHUTDOWN ................................................... 0 Shut Down Procedure ................................................ 0 Short Term Storage ................................................. 0 Long Term Storage .................................................. 0 Attended Long Term Storage ......................................... 0 Unattended Long Term Storage ....................................... 0 TOOL RECOVERY ...................................................... 0 Drill stability charts ............................................. 0 10438_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 Miscellaneous Controls ............................................ 65 Portable Remote Propel Station (Optional) ......................... 65 PORTABLE REMOTE PROPEL STATION ..................................... 65 Hydraulic Reservoir Remote Fill Control Panel ...................... 66 HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL ...................... 66 Lube Control Panel ................................................. 66 LUBE CONTROL PANEL ................................................. 66 Prestart Checks .................................................... 67 EXTERNAL Inspection ............................................... 67 Onboard Inspection ................................................. 69 Prestart Lubrication ............................................... 71 START-UP ........................................................... 72 Machine Start Up .................................................. 72 Machinery Check .................................................... 73 Break-In of New Components ......................................... 73 Rotary Drive unit Break-In ......................................... 73 Hoist/Pulldown Gearcase Break-In ................................... 73 Electric Motor Break-In ............................................ 73 OPERATION ......................................................... 74 Propelling ......................................................... 74 Definitions ........................................................ 74 PROPEL Procedure ................................................... 75 PROPEL CONTROLS - OVERVIEW ......................................... 76 STRAIGHT PROPEL .................................................... 77 GRADUAL RIGHT HAND TURN ............................................ 77 GRADUAL LEFT HAND TURN ............................................. 78 COUNTER-ROTATION LEFT HAND TURN .................................... 79 ENSURE GRADUAL TURNS ARE MADE - 15O INCREMENTS .................... 79 Towing PROCEDURE ................................................... 81 TOWING PROCEDURE ................................................... 81 Cable Reel Operation ............................................... 83 CABLE REEL ......................................................... 83 Leveling .......................................................... 84 LEVELING CONTROLS .................................................. 85 Mast Raising and Lowering .......................................... 86 Mast Raising ....................................................... 86 MAST RAISING/LOWERING CONTROLS ..................................... 87 Mast Lowering ...................................................... 88 MAST CONTROLS TO ADJUST FOR ANGLE DRILLING ......................... 88 Pulldown Machinery Operation ....................................... 90 HOIST/PULLDOWN CONTROLS ............................................ 90 Auxiliary Winch Operation .......................................... 91 WINCH OPERATION CONTROLS ........................................... 91 Pipe Rack Operation ................................................ 92 PIPE RACK OPERATING CONTROLS ....................................... 92 PIPE RACK OPERATION ................................................ 93 Tool Handling ...................................................... 95 Pipe Loading and Unloading ......................................... 95 Drill Tool String Assembly ........................................ 97 TOOL STRING ........................................................ 97 STABILIZER INSTALLATION ............................................ 98 DRILL PIPE INSTALLATION CONTROLS ................................... 98 Breakout Wrench Operation ..........................................101 Drill Tool String Disassembly ......................................103 Adding Additional Drill Pipe .......................................105 Removal of Multiple Section Drill Pipe .............................106 Angle Drilling .....................................................107 ANGLE DRILLING EQUIPMENT ...........................................107 PIPE POSITIONER ....................................................108 JIB CRANE ..........................................................109 Dust Suppression System Operation ..................................110 WATER INJECTION SYSTEM .............................................111 DRILLING ...........................................................112 Vertical Drilling ..................................................112 CONTROLS UTILIZED WHILE DRILLING ...................................112 STARTING The Hole (Collaring) .....................................113 Normal Drilling ....................................................115 Ending the Hole ...................................................116 Ending the Hole (Multiple Pipe Sections) ...........................117 Drilling Difficult Formations ......................................117 Unconsolidated Materials ...........................................118 Wet or Sticky Formations ...........................................120 Angle Drilling ....................................................121 Programmed Drill Control Drilling .................................122 PROGRAMMED DRILL CONTROLS UTILIZED .................................122 Preparing to Move ..................................................123 MACHINE SHUTDOWN ...................................................125 Shut Down Procedure ................................................125 Short Term Storage .................................................126 Long Term Storage ..................................................127 Attended Long Term Storage .........................................128 Unattended Long Term Storage .......................................128 TOOL RECOVERY ......................................................129 Drill stability charts .............................................131 10438_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 Lube Pump Hydraulic Schematic ......................................158 Lubrication Points .................................................159 GEARCASE AND RESERVOIR CAPACITIES ..................................159 Lower works lubrication ............................................160 MAIN FRAME LUBRICATION .............................................161 MAST LUBRICATION ~PART 1 ...........................................162 MAST LUBRICATION ~PART 2 ...........................................163 MAST LUBRICATION ~PART 3 ...........................................164 LUBRICANT CLEANLINESS ..............................................165 LUBRICANT SELECTION ................................................166 ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT .......................167 MPO - Multipurpose OIL .............................................168 RWRL - RUNNING WIRE ROPE LUBRICANT .................................169 HYDO - Hydraulic Oil ...............................................171 PAO Synthetic Hydraulic Fluid ......................................172 Recommended Viscosity vs. OAT Chart ................................172 Paraffinic Base Petroleum Hydraulic Fluid ..........................172 Recommended Viscosity vs. OAT Chart ................................173 10438_4.pdf................................................................. 0 Table of Contents.......................................................194 INTRODUCTION .......................................................196 ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM ......................198 SCHEDULED PREVENTIVE MAINTENANCE PROGRAM ..........................198 General Safety Considerations ......................................199 Maintenance During Machine Operation ...............................199 Maintenance Precautions ............................................200 PREVENTIVE MAINTENANCE FOR Lubrication .............................201 Lubricant CLEANLINESS ..............................................202 Frequency of inspection and maintenance ...........................203 MAINTENANCE SCHEDULES ..............................................203 DAILY Check Points .................................................204 external inspection ................................................204 Onboard Inspection .................................................207 AFTER START-UP INSPECTION .........................................211 WEEKLY CHECK points ................................................212 ON-BOARD INSPECTION ................................................215 Monthly Check Points ...............................................217 semi-ANNUAL Check Points ...........................................219 10438_5.pdf................................................................. 0 Table of Contents.......................................................222 Crawler Belts ......................................................228 Lower Works - Overview .............................................228 Adjustment .........................................................229 Crawler Belt Tension - Checking ....................................229 Crawler Belt Adjustment - Details ..................................230 Link Replacement ..................................................231 Belt Replacement ..................................................232 Crawler Belt Replacement - Details ................................232 Lower Rollers ......................................................233 Lower Roller - Details .............................................233 Repair .............................................................234 Upper Rollers ......................................................235 Upper Roller - Details .............................................235 Repair .............................................................236 Take-up tumblers ...................................................237 Repair .............................................................237 Drive Tumbler ......................................................239 Drive Tumbler and Planetary Gearbox Installation ...................239 Repair .............................................................239 Planetary Gearbox ..................................................240 GEARBOX REMOVAL AND INSTALLATION ...................................240 Planetary Gearbox Mount Bolt Torque Sequence .......................241 Checking/Changing Oil ..............................................242 Planetary Gearbox Oil Check - Details ..............................242 LUBRICANT SPECIFICATIONS ...........................................243 Planetary Gearbox Lubrication Specifications .......................243 Oil Change Intervals ...............................................243 Crawler frames .....................................................244 Repair .............................................................244 Crawler Frame Removal/Blocking .....................................245 Axles ..............................................................246 Equalizer Axle - Details ...........................................246 Repair .............................................................246 Rear Axle - Details ................................................247 Mainframe ..........................................................249 Main Frame - Details ...............................................249 Repair .............................................................250 Bit viewing hatch ..................................................250 Bit Viewing Hatch - Details ........................................250 Mast A-Frame .......................................................251 Repair .............................................................251 Leveling jacks .....................................................252 Leveling Jack - Details ...........................................252 Repair .............................................................253 Machinery House ....................................................256 Repair .............................................................256 Machinery House - Exploded View ....................................257 House ventilation fan and filter ...................................258 Machinery House Ventilation Fan ....................................258 Walkways and Ladders ...............................................259 Retractable Boarding Stairway - Details ............................259 Operator's Cab .....................................................260 Operator's Cab Location Mounting ...................................260 Operator's Seat ....................................................261 Operator's Seat - Adjustments ......................................261 Operator's Controls ................................................261 Operator's Controls ...............................................261 Air Conditioning Unit ..............................................262 Operator's Cab Heating/Air Conditioning Unit .......................262 Hydraulic pump drive ...............................................263 Hydraulic Pump Drive ...............................................263 Hydraulic Pump Drive Gearbox - Details ............................264 Cable Reel .........................................................266 Cable Reel - Details ..............................................266 Cable Reel Hydraulics - Details ...................................267 Level Wind Drive Adjustment .......................................268 Hydraulic Adjustments ..............................................269 Hydraulic Pump Adjustments .........................................269 HYDRAULIC DRIVE START UP INSTRUCTIONS ..............................270 Cable Reel Level Wind - Details ....................................271 Lubrication ........................................................272 Hydraulic Maintenance ..............................................272 Repair .............................................................272 Mast Structure .....................................................273 Repair .............................................................274 Mast Safety Slings .................................................274 Upper Safety Sling ................................................274 Repair .............................................................275 Lower Safety Sling - Optional ......................................275 Rotary Gearcase ....................................................276 Rotary Machinery/Gearcase ..........................................276 Drive Shaft Adjustment ............................................277 Rotary Machinery Intermediate Shaft ................................278 Repair .............................................................279 Remove the upper bearing retainer. .................................279 Rotary Machine Driveshaft - Details .............................283 Rotary Motor .......................................................286 Rotary Drive Motor - Details .......................................286 Rotary Coupling ...................................................288 Repair .............................................................288 Rotary Shock Coupling ..............................................290 Repair .............................................................290 Rotary/Pulldown Guide Frame ........................................292 Rotary Pulldown Guide Frame - Details ..............................292 Guide Roller Adjustment ............................................294 Rack Pinion and Upper Guide Roller - Details .......................294 Lower Guide Rollers - Details ......................................295 Repair .............................................................296 COUPLING ALIGNMENT .................................................299 Pulldown Gearcase ..................................................301 Pulldown Machinery - Overview ......................................301 Repair .............................................................302 Pulldown/Machinery Gearcase and Base ...............................302 Pulldown/Machinery First Intermediate and Shipper Shaft ............303 Pulldown Machinery Second Intermediate Shaft .......................304 Pulldown Machinery Input Shaft .....................................306 Hoist Brake ........................................................309 Inspection .........................................................309 Brake Wear Adjustment ..............................................309 Hoist Brake - Details ..............................................310 Brake Wear Adjustment ..............................................311 Replacement of Friction Discs ......................................311 Disassembly of Magnet Body and Armature ............................312 Re-assembly of Magnet Body and Armature ............................312 PIPE RACKS .........................................................313 RH Pipe Rack - Details .............................................313 LH Pipe Rack - Details .............................................314 Repair .............................................................314 Pipe Rack Variable Equipment .......................................316 Tool Wrench ........................................................317 Tool Wrench - Details ..............................................317 Repair .............................................................318 Breakout Wrench ....................................................319 Repair .............................................................319 GENERAL GUIDELINES FOR DISASSEMBLY .................................319 Auxiliary Winch ....................................................320 Mast Braces ........................................................321 Mast Braces - Details ..............................................321 Repair .............................................................322 Adjustment .........................................................322 Hydraulic System ...................................................323 System Operation ...................................................323 Hydraulic Components - Overview ....................................323 Cylinder Circuit Hydraulic System ..................................324 Propel Circuit Hydraulic System ....................................325 GENERAL MAINTENANCE ................................................325 Hydraulic System Cleanliness .......................................325 Oil Requirements ...................................................326 Oil and Filter Changes .............................................326 Weekly Maintenance Checks ..........................................327 Oil Reservoir Repairs ..............................................327 Leveling Jack Counterbalance Valve Pressure Relieving Procedure ....327 Rear Jacks .........................................................328 Front Jack .........................................................328 Pre-start Inspection ...............................................329 Hydraulic Systems Tests ............................................330 Propel Pump Charge Pressure Check ..................................330 Control Pressure Check .............................................331 Propel Enable Valve and Low Speed Select Check ....................331 Jack Cylinder Check in Manual Mode .................................332 Flow Control Check .................................................333 Jack Cylinder Drift Test ...........................................335 Brake Release Pressure Check .......................................335 Propel Brake Emergency Release Check ...............................336 Propel Pump Main Relief Pressure Check .............................336 Crawler Function Check .............................................337 Bit Viewing Hatch Check ............................................338 Boarding Stair Check ...............................................338 Main Flow Valve Check ..............................................338 Breakout Wrench and Tool Wrench Check ..............................338 Dust Curtain Cylinders .............................................338 Dust Seal Slider ...................................................339 Mast Lock ..........................................................339 Mast Brace Lock Cylinders ..........................................339 A-Frame Lock Cylinders .............................................339 Mast Lock Constant Pressure Check ..................................340 Mast Brace Constant Pressure Check .................................340 A-Frame Lock Constant Pressure Check ...............................340 Mast Raise/Lower ...................................................341 Auxiliary Winch ....................................................342 Hydraulic Central Lube Drive Pressure Check ........................343 Window Guard Function Check ........................................344 Water Injection Drain Valves Check .................................344 Water Injection Pump Function Check ................................344 Water Injection Washdown Check .....................................346 Check Jacks in Auto Level Mode .....................................347 Pipe Rack Position Check ...........................................348 Pipe Rack Lock and Gate Cylinder Port Relief Setting ...............348 Pipe Thread Lubricator Check .......................................348 Pipe Positioner Function Check .....................................349 Center Guide Function Check plus Constant Pressure Check ...........350 Automatic breakout wrench check ....................................351 DUST CONTROL .......................................................351 GENERAL MAINTENANCE ................................................351 Drilling Platforms and Dust Curtains ...............................351 Water Injection ....................................................352 Operation ..........................................................352 Filling Water Tank .................................................352 10438_6.pdf................................................................. 0 Table of Contents.......................................................365 BRAKE HUB INSTALLATION .............................................367 Hub Adapter Pre-Heat Advance Requirements Table ....................368 MOTOR COUPLING INSTALLATION ........................................369 Motor Coupling Pre-Heat Advance Requirements Table .................370 PARALLEL MISALIGNMENT ..............................................371 Checking for Parallel Misalignment .................................371 ANGULAR MISALIGNMENT ...............................................372 Checking for Angular Misalignment ..................................372 MISALIGNMENT Examples ..............................................373 Parallel Misalignment Example ......................................373 Angular Misalignment Example .......................................373 Combination Misalignment Example ...................................373 10438_7.pdf................................................................. 0 Table of Contents.......................................................375 Compressed Air Systems .............................................377 AIR COMPRESSOR .....................................................378 Separator Control Components .......................................379 Air Intake Filter ..................................................380 Oil Drain Valve ....................................................381 VARIABLE VOLUME Control ............................................381 Separator Maintenance ..............................................383 SEPARATOR COVER HARDWARE TIGHTENING PROCEDURE ......................384 ROTARY SCREW COMPRESSOR ............................................385 Compressor Air End Assembly ........................................385 Compressor START-UP ................................................387 Compressor SHUTDOWN Modes ..........................................388 Compressor Failure Fault ...........................................388 Compressor Cooling Failure Fault ...................................388 Compressor Overheat Fault ..........................................388 Compressor Air Temperature Fault ...................................388 THERMOSTATIC CONTROL VALVE .........................................389 INTAKE VALVE, Air End ..............................................391 AIR END INPUT SHAFT OIL SEAL REPLACEMENT ..........................395 INLET REGULATING VALVE .............................................396 AIR PRESSURE CONTROL VALVE .........................................397 DISCHARGE AIR TEMPERATURE GAUGE ....................................397 SAFETY RELIEF VALVE ................................................398 SOLENOID BLOWDOWN VALVE ............................................398 COMPRESSOR OIL STRAINER & FILTERS ..................................398 10438_8.pdf................................................................. 0 Table of Contents.......................................................401 AIR CONDITIONING UNIT ..............................................403 DESCRIPTION .......................................................403 Overview ...........................................................403 Evaporator .........................................................403 Condenser ..........................................................404 Specifications .....................................................404 House Fans .........................................................405 Inspection .........................................................405 Lubrication ........................................................406 10438_9.pdf................................................................. 0 Table of Contents.......................................................407 Capscrew (Bolt) Grade ..............................................409 BOLT TIGHTENING ....................................................410 TORQUE WRENCH METHOD ...............................................410 Table 1 - Lubricated or Plated Threads or with Hardened Washers ....410 Table 2 - Dry Threads ..............................................410 TURN-OF-NUT METHOD .................................................411 Table of Snug Tight Torque Values ..................................411 WIRE LOCKING CAPSCREWS .............................................412 Patterns for Wirelocking Capscrews .................................412 GEAR INSPECTION ....................................................413 Gear Tooth Surface Failures .......................................414 AEROQUIP ORS CONNECTIONS ...........................................415 ORS Connection Assembly ............................................415 Seals ..............................................................416 SEAL INSTALLATION ..................................................416 Gearcase Sealing ...................................................418 MAINTENANCE WELDING ................................................419 WELDING ELECTRODES .................................................420 REPAIR WELDING OF CRACKS ...........................................421 Joint Preparation for Repair of Cracks .............................421 PREHEAT ............................................................422 WELDING TECHNIQUE ..................................................422 REPAIR WELDING OF BROKEN PARTS .....................................423 WELDING AND CUTTING EQUIPMENT ......................................424 STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT .................424 WIRE ROPE Care and Maintenance .....................................426 Storage ...........................................................426 Checking Diameter .................................................426 Correct Method for Checking Wire Rope Diameter .....................426 Handling Wire Rope ................................................427 Improper Methods for Uncoiling Wire Rope ...........................428 End Preparations/Terminations ......................................429 Wire Rope Clips ....................................................430 Wire Rope Clip Application ........................................430 Wedge Sockets .....................................................432 Inspection of Sheaves and Drums ...................................433 Examples of Sheave Groove Conditions ...............................433 Groove Gauge for New or Re-Worked Sheaves ..........................433 Inspecting for Worn Sheave .........................................434 Breaking In a New Wire Rope .......................................434 Inspection Data ....................................................435 Guideline to Inspections and Reports ..............................436 Wire Rope Stretch vs Rope Life .....................................438 Examples of Broken Wires ...........................................441
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