CAT Bucyrus 49RII Electric Blast Hole Drill Mechanical Maintenance Manual BI005490 – PDF DOWNLOAD

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CAT Bucyrus 49RII Electric Blast Hole Drill Mechanical Maintenance Manual BI005490 – PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus 49RII Electric Blast Hole Drill Mechanical Maintenance Manual BI005490 – PDF DOWNLOAD

Language : English
Pages : 365
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus 49RII Electric Blast Hole Drill Mechanical Maintenance Manual BI005490 – PDF DOWNLOAD

FOREWORD:

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

TABLE OF CONTENTS:

CAT Bucyrus 49RII Electric Blast Hole Drill Mechanical Maintenance Manual BI005490 – PDF DOWNLOAD

CHAPTER 1 MECHANICAL MAINTENANCE
SECTION 1 – MAINTENANCE PROCEDURE
General 1-1-1
Maintenance Schedules and Reports 1-1-1
Safety 1-1-2
General 1-1-2
In-operation Maintenance 1-1-2
Precautions Before and During Maintenance Work 1-1-2
SECTION 2 – LOWER WORKS
Crawler Belts 1-2-1
Adjustment 1-2-1
Link Replacement 1-2-4
Belt Replacement 1-2-5
Lower Rollers 1-2-6
Upper Rollers 1-2-7
Take-up Tumblers 1-2-7
Drive Tumbler 1-2-8
Planetary Gearbox 1-2-9
Crawler Frames 1-2-12
Axles 1-2-13
SECTION 3 – MAINFRAME
Mainframe 1-3-1
Bit viewing Hatch 1-3-1
Mast A-Frame 1-3-2
Leveling Jacks , , 1-3-2
Machinery House ; 1-3-6
House Ventilation Fan and Filter 1-3-6
Walkways and Ladders : 1-3-6
Operator’s Cab ; 1-3-8
Operator’s Seat 1-3-8
Operator’s Controls 1-3-9
Ventilation Unit 1-3-9
Hydraulic Pump Drive 1-3-9
Cable Reel 1-3-11
Level Wind Drive Adjustment 1-3-11
Hydraulic Adjustments 1-3-14
Lubrication 1-3-17
Hydraulic Maintenance 1-3-17
Repair 1-3-17
SECTION 4 – MAST
Mast Structure 1-4-1
Mast Safety Slings 1-4-2
Rotary Gearcase 1-4-2
Drive Shaft Adjustment 1-4-3
Repair 1-4-3
Rotary Motor 1-4-8
Rotary Coupling 1-4-9
Rotary Shock Sub (for machines 140916 thru 140976) 1-4-10
Rotary Shock Sub (for machines 140977 and future) 1-4-11
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Propel Circuit Hydraulic System 2-1-1
SECTION 2 – GENERAL MAINTENANCE
Hydraulic System Cleanliness 2-2-1
Oil Requirements 2-2-1
Oil and Filter Changes 2-2-1
Filter Maintenance 2-2-1
Weekly Maintenance Checks 2-2-2
Oil Reservoir Repairs 2-2-2
Leveling Jack Counterbalance Valve Pressure Relieving Procedure 2-2-2
Rear Jacks 2-2-2
Front Jack 2-2-3
Prestart Inspection 2-2-3
Hydraulic Systems Tests 2-2-4
Propel Pump Charge Pressure Check 2-2-4
Control Pressure Check 2-2-4
Propel Enable Valve and Low Speed Select Check 2-2-4
Jack Cylinder Check in Manual Mode 2-2-5
Flow Control Check 2-2-5
Jack Cylinder Drift Test 2-2-6
Brake Release Pressure Check 2-2-6
Propel Brake Emergency Release Check 2-2-6
Propel Pump Main Relief Pressure Check 2-2-7
Crawler Function Check 2-2-7
Bit Viewing Hatch Check 2-2-7
Boarding Stair Check 2-2-7
Main Flow Valve Check 2-2-7
Breakout Wrench and Tool Wrench Check 2-2-7
Dust Curtain Cylinders 2-2-8
Dust Seal Slider 2-2-8
Mast Lock (Station 6 of 7-station manifold) 2-2-8
Mast Brace Lock Cylinders (Station 4 of 7-station manifold) 2-2-8
Rotary/Pulldown Guide Frame 1-4-12
Guide Roller Adjustment 1-4-12
Repair 1-4-16
Pulldown Gearcase 1-4-17
Hoist Brake 1-4-21
Inspection 1-4-21
Brake Wear Adjustment 1-4-21
Replacement of Friction Discs 1-4-22
Disassembly of Magnet Body and Armature 1-4-22
Reassembly of Magnet Body and Armature 1-4-22
Pipe Racks 1-4-23
Tool Wrenches 1-4-24
Casing Tong Jib Crane 1-4-26
Pipe Positioner 1-4-28
Auxiliary Winch 1-4-28
Mast Braces 1-4-30
Repair 1-4-30
Adjustment 1-4-30
CHAPTER 2 HYDRAULIC SYSTEM
SECTION 1 – SYSTEM OPERATION
Cylinder Circuit Hydraulic System 2-1-1
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Main Air System 3-2-1
Intake Air Filter 3-2-1
Filter Replacement 3-2-1
Compressor Radiator 3-2-2
SECTION 3 – ROTARY SCREW COMPRESSOR
(A·C Compressor Corp. KS-31-LU, KS-27-LU, KS-31-AC or KS-27-AC)
Description 3-3-1
Coupling Alignment 3-3-2
Parallel Misalignment 3-3-3
Angular Misalignment 3-3-3
Start-Up Procedure 3-3-3
Shutdown 3-3-4
Controls and Instruments 3-3-4
Air Pressure Control System 3·3-4
Reduced Unloaded Horsepower Feature (LU Design Compressor Only). 3·3-1O
Variable Volume Feature (Optional) 3-3-13
Lubrication System 3-3-15
Compressor Oil System 3-3-15
Lubricant Specifications (LU Design Compressors) 3-3-15
Lubricant Specifications (AC Design Compressors) 3-3-15
Filling Oil System (Initially) 3·3-16
Oil Level Gauge 3·3-16
Adding Oil Between Changes 3-3-16
Oil Change Intervals 3-3-16
Draining Oil System 3-3-16
Refilling Oil System 3-3-17
Compressor Oil Strainer and Filters 3-3-17
Compressor Oil Cooler 3·3-17
Thermostatic Control Valve 3-3-17
Compressor Oil Separator Elements 3-3-19
A-Frame Lock Cylinders (Station 5 of 7-Station Manifold) 2-2-8
Mast Lock Constant Pressure Check 2-2-8
Mast Brace Constant Pressure Check 2-2-8
A-Frame Lock Constant Pressure Check 2-2-8
Mast Raise/Lower 2-2-9
Auxiliary Winch 2-2-9
Hydraulic Central Lube Drive Pressure Check 2-2-10
Window Guard Function Check (Station 1 of 4-Station Manifold) 2-2-10
Water Injection Drain Valves Check (Station 1 of 5-Station Manifold) 2-2-10
Water Injection Pump Function Check 2-2-10
Water Injection Washdown Check (Station 3 of 4-Station Manifold) 2-2-11
Check Jacks in Auto Level Mode 2-2-12
Pipe Rack Position Check 2-2-12
Pipe Rack Lock and Gate Cylinder Port Relief Setting 2-2-12
Pipe Thread Lubricator Check 2-2-13
Pipe Positioner Function Check 2-2-13
Center Guide Functon Check plus Constant Pressure Check 2-2-13
Test Point Locations (for machines thru 141001) 2-2-15
Test Point Locations (for machines 141003 and up) 2-2-16
CHAPTER 3 AIR SYSTEM
SECTION 1 – SYSTEM OPERATION
Main Air System 3-1-1
SECTION 2 – GENERAL MAINTENANCE
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Flow Chart 4-1-4
Operation (for machines 141003 and up) 4-1-4
Filling Water Tank 4-1-4
Deck Washdown System 4-1-5
SECTION 2 – MAINTENANCE OF FILTERICLONE«l (TIPTON)
Operating Principle 4-2-1
Maintenance 4-2-1
CHAPTER 5 LUBRICATION
SECTION 1 – LUBRICATION PROCEDURES
General 5-1-1
Lubricant Cleanliness 5-1-1
Lubrication Points 5-1-1
Lubrication Benchmarks 5-1-8
SECTION 2 – LINCOLN AUTOMATIC SYSTEM
Troubleshooting Systems 5-2-1
Air Locks 5-2-1
Dirty Supply Lines 5-2-1
All Injectors Do Not Function Properly 5-2-1
Mter Venting, the Indicator Sterns on the Injectors Do Not Return to their
Normal Position 5-2-1
Failure of the Pump to Build Up Pressure (Lincoln Pump) 5-2-2
Slow Pressure Rise (Lincoln Pump) 5-2-2
Pump Operation (Lincoln Pump) 5-2-2
Pump Disassembly and Reassembly (Lincoln Pump) 5-2-2
Graco Pump Servicing 5-2-5
Pressure Relief Procedure 5-2-5
Replacing the Throat Seals 5-2-5
Disconnecting the Reciprocator and Displacement Pump 5-2-6
Lubrication 5-2-5
Cold Weather Start System (Option for LU Design Compressors) 3-3-19
Air Filters 3-3-20
Air Filter (Optional) 3-3-23
Maintenance Schedule 3-3-23
Intake Valve Service (for AC Design Units Only) 3-3-24
Air End input Shaft oil Seal Replacement (for AC Design Units Only) 3-3-26
CHAPTER 4 DUST CONTROL
SECTION 1 – GENERAL MAINTENANCE
Drilling Platforms and Dust Curtains 4-1-1
FILTERICLONE«l System (Tipton) 4-1-1
Daily Maintenance Checks 4-1-1
Monthly Maintenance Checks 4-1-1
Six Month Maintenance Checks 4-1-2
Water Injection 4-1-2
Operation (for machines 140916 thru 140962) 4-1-2
Operation (for machines 140963 thru 141001) 4-1-2
Daily Maintenance Check 4-1-3
Weekly Maintenance Check 4-1-3
Bimonthly Maintenance Checks 4-1-3
Fluid Levels 4-1-3
Shaft to Coupling Alignment 4-1-3
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CHAPTER 6 TROUBLESHOOTING 6·1·1
APPENDICES
APPENDIX Al – GEAR INSPECTION
General IA-I
APPENDIX A2 – BOLT TORQUING
Torque Wrench Method 2A-I
Turn of the Nut Method 2A-2
APPENDIX A3 – PINION, BRAKE DRUM AND COUPLING INSTALLATION
Removal from Shaft 3A-I
Mounting on Shaft 3A-I
APPENDIX A4 – LUBE BENCHMARKS
MPG – Multi-Purpose Type Grease 4A-I
ACSL – Air compressor (Screw Type) Lubricant 4A-2
DPTL – Drill Pipe Thread Lubricant 4A-3
MPO – Multi-Purpose Oil 4A-4
OGL – Open Gear Lubricant 4A-5
RGL – Regular Type Gear Lubricant 4A-7
RWRL – Running Wire Rope Lubricant 4A-IO
HYDO – Hydraulic Oil 4A-II
APPENDIX A5 – RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF
PRINCIPAL STRUCTURES ON BLAST HOLE DRILLS
General 5A-I
Maintenance Welding 5A-I
Structural Materials 5A-I
Welding Electrodes 5A-2
Preheat Requirements 5A-2
Removal of Cracks 5A-3
Weld Groove Preparation 5A-3
Drill Pipe Welding 5A-4
Welding Technique 5A-5
Weld Inspection 5A-5
Repair of Broken Parts 5A-5
APPENDIX A6 – PREVENTIVE MAINTENANCE CHECK LIST
Level I Inspection 6A-I
Level 2 Inspection 6A-5
Level 3 Inspection 6A-7
APPENDIX A7 – SPECIAL FITS 7A-I
APPENDIX A8 – AEROQUIP ORS CONNECTIONS 8A-I

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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