Cat BUCYRUS-ERIE 49-RH Blast Hole Drill MECHANICAL MAINTENANCE MANUAL BI005459 – PDF DOWNLOAD

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Cat BUCYRUS-ERIE 49-RH Blast Hole Drill MECHANICAL MAINTENANCE MANUAL BI005459 – PDF DOWNLOAD

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Cat BUCYRUS-ERIE 49-RH Blast Hole Drill MECHANICAL MAINTENANCE MANUAL BI005459 – PDF DOWNLOAD

Language : English
Pages :209
Downloadable : Yes
File Type : PDF

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Cat BUCYRUS-ERIE 49-RH Blast Hole Drill MECHANICAL MAINTENANCE MANUAL BI005459 – PDF DOWNLOAD

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 49-RH drill.

MAINTENANCE SCHEDULES AND 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.
• Schedule 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 paper work 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-ERIE 49-RH Blast Hole Drill MECHANICAL MAINTENANCE MANUAL BI005459 – PDF DOWNLOAD

CHAPTER I-MECHANICAL MAINTENANCE
Section 1 – MAINTENANCE PROCEDURE
General 1
Main’tenance Schedules and Report 1
Sa:f”e’ty’ 2
General 2
In-Operation MaintellmC8 2
Precautions Before and During Maintenance Work 2
Section 2 – LOWERWORKS
Crawler Belts – – 5
Ad jus’tDlent 5
Link Replacement – 6
Belt Replacement 7
! ower Rollers 7
Repair 8
Take-up Tumbler : 8
Repair 9
Drive Tumbler 9
Repair 9
Planeta ry Gearbox — 10
Crawler Fra mes — 14
Repair – 14
Axles 15
Repair — – – 15
Section 3 – MAINFRAME
Ma:infta me 17
Repair 17
Mast A-F’r’ame – – 11
Repair 17
I evelingJacks – — – – 17
Repair – — 17
Machine”, House – – — – 20
Repair I” 21
House Ven’tilauon Fan and Filter 21
Walkways and Ladders — 2l
Operators Cab 22
Opera tors Seat 22
Operators Con’b”oli 22
Ven’tilaaon Unit 22
Hydra ulic Pump Drive Gearbox 22
Altemator —- 25
Power Take-Off – — – 25
Clutch Adjustment — – 26
Lubrication – – — — – 26
Removal and Disassembly 26
Assembly and Insta llation – 29
Diesel Engine 32
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Diesel Engine Radiator 33
General Safety and Maintenance 33
Removal of Tubes 34
Installation ofTubes 34
Core with Centertank 35
External Cleaning 35
Diesel Engine Air Filter 35
Compressor Drive Belt Replacement 35
Diesel Engine Saver 36
Hose Routing and Installation Precautions 36
Section 4 – MAST
Mast Structure 39
Repair 39
Rotary Gearcase 40
Drive Shaft Adjustment 40
Repair 40
Rotary Motor 44
Rotary Coupling 44
Repair 44
Rotary Shock Sub 45
Repair 46
Rotary/Pulldown Guide Frame 46
Guide Roller Adjustment 46
Repair 48
Pulldown Gearcase 50
Repair 50
Hoist Brake 54
Inspection 54
Adjustment 54
Repair 54
Pipe Racks 56
Repair 56
Tool Wrenches 56
Repair 58
Casing Tong Support 59
Auxiliary Winch 61
Mast Braces 61
Repair 61
Adjustment 61
CHAPTER 2 HYDRAULIC SYSTEM
Section 1 – SYSTEM OPERATION
Cylinder Circuit Hydraulic System 63
Propel Circuit hydraulic System 64
Radiator Fan Drive and PrO Clutch System 64
Section 2- GENERAL MAINTENANCE
Hydraulic System Cleanliness 71
Oil Requirements 71
Oil and Filter Changes 71
Weekly Maintenance Checks 71
Oil Reservoir Repairs 72
Prestart Inspection 72
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Hydraulic Systems Tests 72
Propel Pump Charge Pressure 72
Control Pressure Check 73
Propel Enable Valve and High Speed Select Check 73
Jack Cylinder Check In Manual Mode 73
Propel Brake Release Pressure Check 74
Left Track Main Relief Pressure Check 74
Left Track Pressure Override Check , 74
Right Track Main Relief Pressure Check 75
Right Track Pressure Override Check 75
Propel Brake Emergency Release Check 75
Mass Latch Cylinders 76
Dust Curtain Cylinders 76
A-Frame Latch Cylinders 76
Mast Brace Latch Cylinders 76
Mast Hoist 76
Auxiliary Winch 77
Pipe Rack Position 77
Pipe Rack Lock and Gate Cylinder Port Relief Setting 77
Leveling Jacks In Auto Level Mode 77
Test Point Location Chart 79
Section 3 – COMPONENT MAINTENANCE
Cylinder Circuit Hydraulic Pump Overhaul 81
General 81
Single Pump Disassembly 81
Single Pump Inspection 82
Single Pump Assembly 83
Dual Pump Disassembly 84
Dual Pump Inspection ; 85
Dual Pump Assembly 85
Hydraulic Oil Cooler 87
General Safety and Maintenance 87
Removal of Tubes 88
Installation ofTubes 88
External Cleaning 89
CHAPTER 3 AIR SYSTEMS
Section 1 – SYSTEMS OPERATION
General 91
Main Air System 91
Auxiliary Air System 91
Safety 91
Section 2 – GENERAL MAINTENANCE
Main Air System 93
General 93
Intake Air Filter 93
Filter Replacement 93
Compressor Radiator 94
Auxiliary Air System 94
Auxiliary Air Compressor 94
Miscellaneous Components 95
Unloader Check Valve Service 95
Air Tanks 95
Air Tank Valves 95
Pressure Switch 95
Filter 95
Anti-Freezer 96
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Section 3 – AUXILIARY AIR COMPRESSOR (COMPAIR-KELLOGG) B352
Disassembly of Pump 97
Fitting and Reassembly 98
Section 4 – AUXILIARY AIR COMPRESSOR (COMPAIR-KELLOGG) B462
Head Value Service 101
Piston Ring Service 101
Overhaul Procedure 102
Reassembly 102
Section 5 – ROTARY SCREW COMPRESSOR (A-C COMPRESSOR CORP )
Description 105
Coupling Alignment 105
Start-Up Procedure 106
Controls and Instruments 107
Reduced Unloader Horsepower Feature 113
Variable Volume Feature 115
Lubrication System 116
Air Filters 122
Maintenance Schedule 124
CHAPTER 4 DUST CONTROL
Section 1 – GENERAL MAINTENANCE
Drilling Platforms and Dust Curtains 131
Water Injection 131
Operation 131
CHAPTER 5· LUBRICATION
Section 1 – LUBRICATION PROCEDURES
General 133
Lubricant Cleanliness 133
Lubrication Points 133
Lubricant Benchmarks 134
Lubrication Charts
Gearcase and Reservoir Capacities 134
Lower Works 135
Mainframe 136
Mast (Part 1) 137
Mast (Part 2) 138
Mast (Part 3 139
Section 2 – LINCOLN AUTOMATIC SYSTEM
TROUBLESHOOTING SYSTEMS 141
Air Locks 141
Dirty Supply Lines 141
All Injectors Do Not Function Properly 141
Mter Venting, the Indicator Stems on the Injectors
Do Not Return to Their Normal Position 141
Failure of Pump to Build Up Pressure 142
Sluggish Pump Operation 142
Slow Pressure Rise 142
Assembly ofTubing Compression Fitting 142
Principle of Operation Pump Air Motor 142
Service of Lower Pumping Unit 144
Lubrication 145
Installation, Operating, and Maintenance Instructions 145
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CHAPTER6·TROUBLSHOOTING
General 149
Drilling 149
Rotary Drive Unit 151
Pulldown Unit Hoist Brake 154
Mast 154
Main Air Compress9r (screw type) 155
Auxiliary Air Compressor 157
Hydraulic System 158
Hydraulic Oil Cooler 159
Hydraulic Cylinder 160
Hydraulic Pump (Cylinder Circuit) 160
Hydraulic Pump (Propel Circuit) 161
APPENDICES
Appendix AI – GEAR INSPECTION 1A
Appendix A2 – BOLT TORQUING
Torque Wrench Method 3A
Turn-Of-The-Nut Method 4A
Appendix A3 – PINION, BRAKE DRUM, AND COUPLING INSTALLATION
Removal From Motor Shaft 5A
Mounting on Shaft 5A
Appendix A4 – LUBE BENCHMARKS
Multipurpose Type Grease (MPG) 9A
Air Compressor (vane type) Lubricant (ACVL) 10A
Air Compressor (screw type) Lubricant (ACSL) l1A
Chain Drive Lubricant (CDL) 12A
Drill Pipe Thread Lubricant (DPTL) 13A
Multipurpose Oil (MPO) 14A
Open Gear Lubricant (OGL) 14A
Regular Type Gear Lubricant (RGL) 16A
Running Wire Rope Lubricant (RWRL) 20A
Hydraulic Oil (HYDO) 21A
Appendix A5 – RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OR PRINCIPAL
STRUCTURES ON BLAST HOLE DRILLS
General ‘” 23A
Maintenance Welding 23A
Structural Materials 23A
Welding Electrodes 24A
Preheat Requirements 26A
Removal of Cracks 26A
Weld Groove Preparation 26A
Drill Pipe Welding 26A
Welding Technique 28A
Weld Inspection 28A
Repair of Broken Parts 28A
Methods of Repair of Cracks 28A
Appendix A6 – PREVENTIVE MAINTENANCE CHECKLISTS
Level I Inspection 29A
Level II Inspection 34A
Level III Inspection 36A
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Appendix A7 – SPECIAL DRAWINGS (BEARING FITS)
Pulldown First Intermediate and Shipper Shaft 39A
Pulldown Input Shaft 39A
Pulldown Second Intermediate Shaft 39A
Rotary Gearcase Shafts 40A
Lower Guide Rollers 41A
Upper Guide Rollers and Shipper Shaft 41A
Appendix AS – INSTALLATION AND REMOVAL INSTRUCTIONS FOR DODGE PILLOW
BLOCKBEARINGS 43A
Appendix A9 – MOUNTING AND REMOVAL INSTRUCTIONS FOR “QD” TYPE PULLEY WITH “J”
TYPE BUSHING 7A

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