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Cat BUCYRUS 59R ELECTRIC BLAST HOLE DRILL MECHANICAL MAINTENANCE MANUAL BI616757 – PDF DOWNLOAD
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Cat BUCYRUS 59R ELECTRIC BLAST HOLE DRILL MECHANICAL MAINTENANCE MANUAL BI616757 – PDF DOWNLOAD
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Cat BUCYRUS 59R ELECTRIC BLAST HOLE DRILL MECHANICAL MAINTENANCE MANUAL BI616757 – PDF DOWNLOAD
Language : English
Pages :166
Downloadable : Yes
File Type : PDF
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Cat BUCYRUS 59R ELECTRIC BLAST HOLE DRILL MECHANICAL MAINTENANCE MANUAL BI616757 – PDF DOWNLOAD
CHAPTER 1 MECHANICAL MAINTENANCE
SECTION 1 – MAINTENANCE PROCEDURE
GENERAL
This section of the manual describes those aspects of preventive maintenance such as scheduled reports and safety precautions as they pertain to the 59-R drill.
MAINTENANCESCHEDULESAND REPORTS
- Ideally, all maintenance should be approached from the preventive standpoint and on a regularly scheduled basis. Obviously, this approach keeps downtime to a minimum and results in reduced maintenance costs.
- To establish a preventive upkeep program, scheduled inspections and an operator’s daily report are the most useful tools available. Scheduled inspections should be conducted by the Mine Mechanical and Electrical Maintenance Departments since they are the most qualified.
- Either department should generate a certain amount of paperwork such as inspection records that become a part of the mine’s permanent file on the machine. The inspection records should be explicit, complete, and cover every part of the machine.
- Each machine operator should complete a daily record of the machine’s performance. This record should include time worked, time down, reasons for all delays, and observations on any unusual conditions encountered during operation.
- From these records, items that can potentially cause machine downtime can be corrected or prevented immediately, or scheduled for a future date when the machine availability can be coordinated with the other mine activities.
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TABLE OF CONTENTS:
Cat BUCYRUS 59R ELECTRIC BLAST HOLE DRILL MECHANICAL MAINTENANCE MANUAL BI616757 – PDF DOWNLOAD
COVER PAGE.................................................................................. 1 TABLE OF CONTENTS........................................................................... 2 MECHANICAL MAINTENANCE...................................................................... 7 MAINTENANCE PROCEDURE................................................................... 7 GENERAL............................................................................. 7 MAINTENANCE SCHEDULES AND REPORTS............................................... 7 SAFETY.............................................................................. 9 GENERAL......................................................................... 9 IN-OPERATION MAINTENANCE........................................................ 9 PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK.................................. 9 LOWER WORKS............................................................................. 10 CRAWLER BELTS....................................................................... 10 ADJUSTMENT...................................................................... 10 LINK REPLACEMENT................................................................ 12 BELT REPLACEMENT................................................................ 13 LOWER ROLLERS....................................................................... 14 UPPER ROLLERS....................................................................... 15 TAKE-UP TUMBLERS.................................................................... 16 DRIVE TUMBLERS...................................................................... 17 PLANETARY GEAR BOX.................................................................. 19 CRAWLER FRAMES...................................................................... 21 AXLES............................................................................... 23 MAINFRAME............................................................................... 26 MAINFRAME........................................................................... 26 BIT VIEWING HATCH................................................................... 26 MAST A-FRAME........................................................................ 27 LEVELING JACKS...................................................................... 27 MACHINERY HOUSE..................................................................... 30 HOUSE VENTILATION FAN AND FILTER.................................................... 31 WALKWAYS AND LADDERS................................................................ 31 OPERATOR'S CAB...................................................................... 32 OPERATOR'S SEAT................................................................. 32 OPERATOR'S CONTROLS............................................................. 32 VENTILATION UNIT................................................................ 32 HYDRAULIC PUMP DRIVE................................................................ 33 CABLE REEL.......................................................................... 35 LEVEL WIND DRIVE ADJUSTMENT..................................................... 35 HYDRAULIC ADJUSTMENTS........................................................... 35 LUBRICATION..................................................................... 38 HYDRAULIC MAINTENANCE........................................................... 38 REPAIR.......................................................................... 38 MAST.................................................................................... 42 MAST STRUCTURE...................................................................... 42 MAST SAFETY SLING................................................................... 43 ROTARY GEARCASE..................................................................... 43 DRIVE SHAFT ADJUSTMENT.......................................................... 43 REPAIR.......................................................................... 44 ROTARY MOTOR........................................................................ 49 ROTARY COUPLING..................................................................... 49 ROTARY SHOCK SUB.................................................................... 50 ROTARY/PULLDOWN GUIDE FRAME......................................................... 52 GUIDE ROLLER ADJUSTMENT......................................................... 52 REPAIR.......................................................................... 52 PULLDOWN GEARCASE................................................................... 56 HOIST BRAKE......................................................................... 61 INSPECTION...................................................................... 61 BRAKE WEAR ADJUSTMENT........................................................... 61 REPLACEMENT OF FRICTION DISCS................................................... 61 DISASSEMBLY OF MAGNET BODY ARMATURE............................................. 62 REASSEMBLY OF MAGNET BODY ARMATURE.............................................. 62 PIPE RACKS.......................................................................... 63 TOOL WRENCHES....................................................................... 64 AUXILIARY WENCH..................................................................... 65 MAST BRACES......................................................................... 65 REPAIR.......................................................................... 65 ADJUSTMENT...................................................................... 67 HYDRAULIC SYSTEM............................................................................ 68 SYSTEM OPERATION........................................................................ 68 CYLINDER CIRCUIT HYDRAULIC SYSTEM................................................... 68 PROPEL CIRCUIT HYDRAULIC SYSTEM..................................................... 68 GENERAL MAINTENANCE..................................................................... 70 HYDRAULIC SYSTEM CLEANLINESS........................................................ 70 OIL REQUIREMENTS.................................................................... 70 OIL AND FILTER CHANGES.............................................................. 70 FILTER MAINTENANCE.................................................................. 70 WEEKLY MAINTENANCE CHECKS........................................................... 71 OIL RESERVOIR REPAIRS............................................................... 71 LEVELING JACK COUNTERBALANCE VALVE PRESSURE RELIEVING PROCEDURE..................... 71 REAR JACKS...................................................................... 71 FRONT JACKS..................................................................... 72 PRE-START INSPECTION................................................................ 72 HYDRAULIC SYSTEMS TESTS............................................................. 73 PROPEL PUMP CHARGE PRESSURE CHECK............................................... 73 CONTROL PRESSURE CHECK.......................................................... 73 PROPEL ENABLE VALVE AND LOW SPEED SELECT CLOCK.................................. 73 JACK CYLINDER CHECK IN MANUAL MODE.............................................. 74 FLOW CONTROL CHECK.............................................................. 74 JACK CYLINDER DRIFT TEST........................................................ 75 BRAKE RELEASE PRESSURE CHECK.................................................... 75 PROPEL BRAKE EMERGENCY RELEASE CHECK............................................ 75 PROPEL PUMP MAIN RELIEF PRESSURE CHECK.......................................... 76 CRAWLER FUNCTION CHECK.......................................................... 76 BIT VIEWING HATCH CHECK......................................................... 76 BOARDING STAIR CHECK............................................................ 76 BREAKOUT WRENCH AND TOOL WRENCH CHECK........................................... 76 DUST CURTAIN CYLINDERS.......................................................... 76 DUST SEAL SLIDER................................................................ 76 MAST LOCK....................................................................... 76 MAST BRACE LOCK CYLINDERS....................................................... 76 A-FRAME LOCK CYLINDERS.......................................................... 76 MAST LOCK CONSTANT PRESSURE CHECK............................................... 76 MAST BRACE CONSTANT PRESSURE CHECK.............................................. 76 A-FRAME LOCK CONSTANT PRESSURE CHECK............................................ 76 MAST RAISE/LOWER................................................................ 78 AUXILIARY WENCH................................................................. 78 HYDRAULIC CENTRAL LUBE DRIVE PRESSURE CHECK..................................... 79 WINDOW GUARD FUNCTION CHECK..................................................... 79 WATER INJECTION DRAIN VALVES CHECK.............................................. 79 WATER INJECTION PUMP FUNCTION CHECK............................................. 79 CHECK JACK IN AUTO LEVEL MODE................................................... 80 PIPE RACK POSITION CHECK........................................................ 81 PIPE RACK LOCK AND GATE CYLINDER PORT RELIEF SETTING............................ 81 TEST POINT LOCATIONS............................................................ 82 AIR SYSTEM.................................................................................. 84 SYSTEM OPERATION........................................................................ 84 MAIN AIR SYSTEM..................................................................... 84 GENERAL MAINTENANCE..................................................................... 85 MAIN AIR SYSTEM..................................................................... 85 INTAKE FILTER....................................................................... 85 COMPRESSOR RADIATOR................................................................. 86 ROTARY SCREW COMPRESSOR................................................................. 87 DESCRIPTION......................................................................... 87 COUPLING ALIGNMENT.................................................................. 87 PARALLEL MISALIGNMENT............................................................... 88 ANGULAR MISALIGNMENT................................................................ 88 START-UP PROCEDURE...................................................................... 88 SHUTDOWN................................................................................ 89 CONTROLS AND INSTRUMENTS................................................................ 89 AIR PRESSURE CONTROL SYSTEM......................................................... 89 REDUCED UNLOADED HORSEPOWER FEATURE................................................. 94 VARIABLE VOLUME FEATURE (OPTIONAL).................................................. 96 LUBRICATION SYSTEM...................................................................... 97 COMPRESSION OIL SYSTEM.............................................................. 97 OIL SPECIFICATIONS.................................................................. 97 FILLING OIL SYSTEM (INITIALLY)...................................................... 97 OIL LEVEL GAUGE..................................................................... 97 ADDING OIL BETWEEN CHANGES.......................................................... 98 OIL CHANGE INTERVALS................................................................ 98 DRAINING OIL SYSTEM................................................................. 98 REFILLING OIL SYSTEM................................................................ 98 COMPRESSOR OIL STRAINER AND FILTERS................................................. 98 COMPRESSOR OIL COOLER............................................................... 99 COMPRESSOR OIL SEPARATOR............................................................ 99 COLD WEATHER START SYSTEM (OPTION)..................................................100 AIR FILTERS.........................................................................100 MAINTENANCE SCHEDULE................................................................102 DUST CONTROL................................................................................104 GENERAL MAINTENANCE.....................................................................104 DRILLING PLATFORMS AND DUST CURTAINS................................................104 FILTER/CLONE SYSTEM (TIPTON)........................................................104 DAILY MAINTENANCE CHECKS........................................................104 MONTHLY MAINTENANCE CHECKS......................................................104 SIX MONTH MAINTENANCE CHECKS....................................................105 WATER INJECTION.....................................................................105 OPERATION.......................................................................105 DAILY MAINTENANCE CHECK.........................................................106 WEEKLY MAINTENANCE CHECKS.......................................................106 BIMONTHLY MAINTENANCE CHECKS....................................................106 FLUID LEVELS....................................................................106 SHAFT TO COUPLING ALIGNMENT.....................................................106 FLOW CHART......................................................................106 FILLING WATER TANK..................................................................107 DECK WASHDOWN SYSTEM................................................................107 MAINTENANCE OF FILTER/CLONE (TIPTON)....................................................108 OPERATING PRINCIPLE.................................................................108 LUBRICATION.................................................................................110 LUBRICATION PROCEDURES..................................................................110 GENERAL.............................................................................110 LUBRICATION CLEANLINESS.............................................................110 LUBRICATION POINTS..................................................................110 LUBRICATION BENCHMARKS..............................................................117 LINCOLN AUTOMATIC SYSTEM................................................................118 TROUBLESHOOTING SYSTEMS.............................................................118 AIR LOCKS.......................................................................118 DIRTY SUPPLY LINES..............................................................118 ALL INJECTORS DO NOT FUNCTION PROPERLY..........................................118 AFTER VENTING, INDICATOR STEMS ON INJECTORS DO NOT RETURN TO NORMAL POSITION....118 FAILURE OF PUMP TO BUIL UP PRESSURE.............................................119 SLWO PRESSURE RISE..............................................................119 PUMP OPERATION..................................................................119 PUMP DISASSEMBLY AND REASSEMBLY.....................................................119 LUBRICATION.....................................................................122 TROUBLE SHOOTING............................................................................124 APPENDICES..................................................................................133 GEAR INSPECTION.........................................................................133 BOLT TORQUING...........................................................................135 TORQUE WRENCH METHOD................................................................135 TURN-OR-THE-NUT METHOD..............................................................136 PINION, BRAKE DRUM, AND COUPLING INSTALLATION...........................................137 REMOVAL FROM SHAFT..................................................................137 MOUNTING ON SHAFT...................................................................137 LUBE BENCHMARKS.........................................................................140 MPG- MULTI PURPOSE TYPE GREASE......................................................140 ACSL- AIR COMPRESSOR (SCREW TYPE) LUBRICANT.........................................141 DPTL- DRILL PIPE THREAD LUBRICANT...................................................142 MPO- MULTI-PURPOSE OIL..............................................................143 OGL- OPEN GEAR LUBRICANT............................................................144 RGL- REGULAR TYPE GEAR LUBRICANT....................................................146 RWRL- RUNNING WIRE ROPE LUBRICANT...................................................149 SPECIAL REQUIREMENTS................................................................149 HYDO- HYDRAULIC OIL.................................................................150 PROCEDURES, MAINT. WELDING, PRINCIPAL STRUCTURES ON BLAST HOLE DRILLS...................153 GENERAL.............................................................................153 MAINTENANCE WELDING.................................................................153 STRUCTURAL MATERIALS................................................................153 WELDING ELECTRODES..................................................................154 PREHEAT REQUIREMENTS................................................................154 REMOVAL OF CRACKS...................................................................155 WELD GROOVE PREPARATION.............................................................155 DRILL PIPE WELDING..................................................................156 WELDING TECHNIQUE...................................................................157 WELD INSPECTION.....................................................................157 REPAIR OF BROKEN PARTS..............................................................157 PREVENTIVE MAINTENANCE CHECKLIST........................................................158 LEVEL 1 INSPECTION..................................................................158 LEVEL 2 INSPECTION..................................................................162 LEVEL 3 INSPECTION..................................................................164 SPECIAL FITS............................................................................165
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