MECHANICAL MAINTENANCE
BI379581
·... : ·_ . . BUCYRUS-ERIE ®
Electric Blast Hole Drill
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BI379581
Electric Blast Hole Drill
BI379581 ·
..,_:-BUCYRUS-ERIE ' ' -·-· -· _; "'' ®
MECHANICAL MAINTENANCE
BI379581 ( (
FOREWORD
The purpose of this manual is to provide information concerning the general maintenance of the 49-R rotary blast hole drill.
The 49-R 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 equipment necessary to propel the drill. The mainframe includes the hydraulic, main air and auxiliary air systems, and the machinery house. The machinery house encloses the majority of the mechanical equipment necessary for the main and auxiliary air systems, the hydraulic systems and electrical control systems .. The machinery house is pressurized with filtered air to minimizE? dirt and heat build-up. The cab, mounted to the mainframe, provides the operator's station, and enclosed 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 .A 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 hazard 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 Company 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 Bucyr1,1s-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 component 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 products. For this reason changes may have been made to the machine or its equipment that are not detailed in this manual.
MACHINE SERIAL NUMBER---------------------
REVISED 6/30/88
BUCYRUS-ERIE COMPANY
General Offices: South Milwaukee, Wisconsin, U.S.A
OSM BECOM 687
BI379581
Lit. S353
BI379581 (
TABLE OF CONTENTS
BI379581
CHAPTER 1 MAINTENANCE PAGE Section 1- MECHANICAL PROCEDURE General ................................................................................................................................................ 1 Maintenance Schedules and Reports ................................................................................................. 1 Safety : , : 2 General ........................................................................................................................................... 2 In-Operation Maintenance ........................................................................................................... 2 Precautions Before and During Maintenance Work ................................................................... 2 Section 2 - LOWER WORKS Crawler Belts 5 Adjustments Take-up Tumbler 5 Link Replacement 6 Belt Replacement 7 Lower Rollers 7 Repair ............................................................................................................................................ 8 Takeup Tumbler ................................................................................................................................ 11 Repair ............................................................................................................................................ 9 Drive Tumblers ................................................................................................................................... 9 Repair ............................................................................................................................................ 9 Planetary Gearbox ............................................................................................................................ 10 Crawler Frames 14 Repair 14 Axles ................................................................................................................................................. 15 Repair .......................................................................................................................................... 15 Section 3 - MAINFRAME Mainframe ......................................................................................................................................... 17 Repair 17 Mast A-Frame 17 Repair 17 Leveling Jacks 17 Repair 17 Machinery House 20 Repair 21 House Ventilation Fan and Filter 21 Walkways and Ladders 21 Operator's Cab 22 Operator's Seat :22 Operator's Controls Ventilation Unit .......................................................................................................................... 22 Hydraulic Pump Drive ...................................................................................................................... 22 Cable Reel .......................................................................................................................................... 24 Repair .......................................................................................................................................... 25 Section 4 -MAST Mast Structure 29 Repair 29 Rotary Gearcase 30 Drive Shaft Adjustment 30 Repair : 30
BI379581 Rotary Motor ...................................................................................................................................... 34 Rotary Coupling ................................................................................................................................ 34 ( Repair 34 Rotary Shock Sub 35 Repair 36 Rotary/Pulldown Guide Frame 36 Guide Roller Adjustment 36 Repair 38 Pull down Gearcase 40 Repair 40 Hoist Brake 44 Inspection 44 Adjustment .................................................................................................................................. 44 Repair .......................................................................................................................................... 44 Pipe Racks ......................................................................................................................................... 46 Repair .......................................................................................................................................... 46 Tool Wrenches ................................................................................................................................... 46 Repair 48 Casing Tong Support 49 Pipe Positioner ; 49 Auxiliary Winch 51 Mast Braces , 52 Repair , 52 Adjustment 52 CHAPTER 2 - HYDRAULIC SYSTEM Section 1 - SYSTEM OPERATION Cylinder Circuit Hydraulic System , 55 Propel Circuit Hydraulic System 56 Section 2 - GENERAL MAINTENANCE Hydraulic System Cleanliness .......................................................................................................... 63 Oil Requirements .............................................................................................................................. 63 Oil and Filter Changes ...................................................................................................................... 63 Weekly Maintenance Checks ............................................................................................................ 63 Oil Reservoir Repairs ........................................................................................................................ 64 Pre start Inspection ............................................................................................................................ 64 Hydraulic System Tests .................................................................................................................... 64 Propel Pump Charge Pressure (Rexroth Pumps only) 64 Propel Pump Charge Pressure (Sundstrand Pumps only) 64 Control Pressure Check 65 Propel Enable Valve and High Speed Select Check 65 Jack Cylinder Check In Manual Mode 65 Propel Brake Release Pressure Check 66 Left Track Main Relief Pressure Check (Rexroth Pumps only) 66 Left Track Main Relief Pressure Check (Sundstrand Pumps only) ......................................... 67 Left Track Pressure Override Check (Rexroth Pumps only) .................................................... 67 Left Crawler Track Sprocket RPM Check (Sundstrand Pumps only) ...................................... 67 Right Track Main Relief Pressure Check (Rexroth Pumps only) ............................................. 68 Right Track Main Relief Pressure Check (Sundstrand Pumps only) ....................................... 68 Right Track Pressure Override Check (Rexroth Pumps only) .................................................. 68 Right Crawler Track Sprocket RPM (Sundstrand Pumps only) ............................................... 69 ( Propel Brake Emergency Release Check ................................................................................... 69 Mast Latch Cylinders ................................................................................................................. 69
BI379581 Dust Curtain Cylinders .............................................................................................................. 69 A-Frame Latch Cylinders .:. 69 Mast Brace Latch Cylinders , 69 Mast Hoist· : 70 Auxiliary Winch : 70 Pipe Rack Position 70 Pipe Rack Lock and Gate Cylinder Port Relief Setting 70A Cable Reel ................................................................................................................................. 70A Leveling Jacks In Auto Level Mode ........................................................................................ 7OA Test Point Location Chart 70B Section 3 -COMPONENT MAINTENANCE Cylinder Circuit Hydraulic Pump Overhaul 71 General 71 Single Pump Disassembly .......................................................................................................... 71 Singe Pump Inspection 72 Single Pump Assembly 73 Dual Pump Disassembly ............................................................................................................ 74 Dual Pump Inspection ................................................................................................................ 75 Dual Pump Assembly 75 Cable Reel Hydraulic Pump 77 General ........................................................................................................................................ 77 Disassembly ................................................................................................................................ 78 Inspection .................................................................................................................................... 79 Assembly 79 Cable Reel Hydraulic Motor 79 Disassembly ................................................................_................................................................ 79 Cleaning and Inspection 81 Reassembly 81 Hydraulic Oil Cooler ......................................................................................................................... 82 Weekly Maintenance Check 82 1000 Hour Maintenance Check .................................................................................................. 82 Yearly Maintenance Check ........................................................................................................ 82 CHAPTER 3 - AIR SYSTEMS Section 1 - SYSTEMS OPERATIONS General 83 Main Air System 83 Auxiliary Air System 83 Safety 83 Section 2 - GENERAL MAINTENANCE Main Air System 87 General 87 Intake Air Filter- Box Type 87 Intake Air Filter- Tubular Type 87 Compressor Radiator 88 Auxiliary Air System 88 Auxiliary Air Compressor ........................................................................................................... 88 Miscellaneous Components ............................................................................................................... 89 Unloader Check Valve Service ................................................................................................... 89 Air Tanks ..................................................................................................................................... 90 Air Tank Valves .......................................................................................................................... 90 Pressure Switch 90 Filter 90 Anti-Freezer 90
BI379581 Section 3 -AUXILIARY AIR COMPRESSOR (COMPAIR-KELLOGG) B352 Disassembly 91 Fitting and REassembly 92 ( Section4- AUXILIARY AIR COMPRESSOR (COMPAIR-KELLOGG) B462 Head Value Service 95 Piston Ring Service 95 Overhaul Procedure 96 Reassembly 96 Section 5- ROTARY VANE COMPRESSOR (A-C COMPRESSOR CORP.) 1000 Hour Maintenance Check 99 4000 Hour Maintenance Check 100 Blade Protection in Idle Units 102 Rotor Alignment for Redoweling 102 Rotor Field Redoweling ............................................................................................................ 103 Section 6- ROTARY SCREW COMPRESSOR (A-C COMPRESSOR CORP.) Description 105 Coupling Alignment 105 Start-Up Procedure ................................................................................................................... 106 Controls and Instruments ........................................................................................................ 107 Lubrication System 113 Air Filters 119 Maintenance Schedule 120 CHAPTER 4 - TROUBLESHOOTING ( Section 1 - GENERAL MAINTENANCE Drilling Platforms and Dust Curtains ........................................................................................... 127 Filter/Clone® System (Tipton) 127 Daily Maintenance 127 Monthly Maintenance Checks 127 Six Month Maintenance Checks .............................................................................................. 127 Water Injection ................................................................................................................................ 128 Operation 128 Section 2- MAINTENANCE OF FILTER/CLONE® (TIPTON) Operating Principles ....................................................................................................................... 129 Maintenance 129 CHAPTER 5 -LUBRICATION Section 1- LUBRICATION General ............................................................................................................................................ 131 Lubricant Cleanliness ..................................................................................................................... 131 Lubrication Points ........................................................................................................................... 131 LubricantBenchmarks ................................................................................................................... 132 Lubrication Charts Gearcase and Reservoir Capacities .......................................................................................... 132 Lower Works ............................................................................................................................. 133 Mainframe 134 Mast (Part 1) 135 ( Mast (Part 2) 136 Mast (Part 3) 137
BI379581 Section 2 - LINCOLN AUTOMATIC SYSTEM Troubleshooting Systems 139 Air Locks ................................................................................................................................... 139 Dirty Supply Lines .................................................................................................................... 139 All Injectors DoN ot Function Properly 139 After Venting, the Indicator Stems on the Injectors Do Not Return to Their Normal Position 139 Failure of Pump to Build Up Pressure 140 Sluggish Pump Operation 140 Slow Pressure Rise 140 Assembly of Tubing Compression Fittings 140 Principle of Operation- Pump Air Motor ................................................................................ 140 Service of Lower Pumping Unit ............................................................................................... 142 Lubrication ................................................................................................................................ 143 Installation, Operating, and Maintenance Instructions ......................................................... 143 Section 3 - TRABON AUTOMATIC SYSTEM Locating Blockage in System .......................................................................................................... 14 7 Terminology .............................................................................................................................. 14 7 Procedure .................................................................................................................................. 14 7 Torque Information in Foot Pounds ............................................................................................... 150 Section 4- VANE TYPE MAIN COMPRESSOR LUBRICATOR Operation and Adjustment ............................................................................................................. 151 To Start Lubricator ................................................................................................................... 15l To Adjust Lubricator ................................................................................................................ 151 Sight Feed Unit ......................................................................................................................... 151 Purging Oil From Pumping Unit ............................................................................................. 151 Care of Lubricator ..................................................................................................................... 152 CHAPTER.6- TROUBLESHOOTING General ............................................................................................................................................ 153 Drilling 153 Rotary Drive Unit 155 Pulldown Unit 156 Pull down Unit Hoist Brake 158 Mast 158 Main Air Compressor (vane type) 159 Main Air Compressor (screw type) ................................................................................................. 161 Auxiliary Air Compressor ............................................................................................................... 164 Hydraulic System ............................................................................................................................ 165 Hydraulic Oil Cooler ....................................................................................................................... 166 Hydraulic Cylinder 167 Hydraulic Pump (Cylinder Circuit) 167 Hydraulic Pump (Propel Circuit) Cable Reel Hydraulic Motor ........................................................................................................... 169 Filter/Clone® ................................................................................................................................... 170
APPENDICES
BI379581
Appendix Al - GEAR INSPECTION lA AppendixA2- 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 AppendixA4- LUBE BENCHMARKS Multipurpose Type Grease (MPG) 9A Air Compressor (vane type) Lubricant (ACVL) ............................................................................. lOA Air Compressor (screw type) Lubricant (ACSL) llA Chain Drive Lubricant 0000 00 00 00 00 0000 00 0000 00 00 00.00 0000 00 0000 12A Drill Pipe Thread Lubricant (DPTL) OOOOooOOOOooOOOO 000 00000000 00 000000 0000 13A Multipurpose Oil (MPO) oooooooooo oo OOOOOOOOOOooOOOOooOOOOooooOOOooooooooooooooOooooooooooooo•• oo••ooooooooooooo oooo.14A Open Gear Lubricant (OGL) oo oo oooo oooooo oo oooooooooooooo•• ooooooooOOO l4A Regular Type Gear Lubricant (RGL) 00 oo oo oo oo oo oo l6A Running Wire Rope Lubricant (RWRL) 00 00 00000000 20A Hydraulic Oil (HYDO) oo oooo oo oo oo oo 21A Appendix A5 -RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OR PRINCIPAL STRUCTURES ON BLAST HOLE DRILLS General oo• 00 00 23A Maintenance Welding 23A Structural Materials 000 23A Welding Electrodes 0000 00 0000 00 00 00 00 0000 00 0000 00 00 000 24A Preheat Requirements oo• 26A Removal of Cracks 00 00 26A Weld Groove Preparation 000 26A Drill Pipe Welding oooooooo oo oo oooo oo oo oo oo oooo000000000 26A Welding Technique 28A Weld Inspection 000 28A Repair of Broken Parts ooooooooOOooOOOOoo OOOO oo oooo oo.oooo oo ooOoooooo00000000000000 oo.oo•oooo28A Methods of Repair of Cracks 00 00 000000 00 000000 00 000.000000 0000 00 0000 28A Appendix A6 -PREVENTIVE MAINTENANCE CHECKLISTS Level I Inspection 29A Level II Inspection 34A Level III Inspection ...... 0000 ..... 000 00 ....... 00 ................ 00 ..... 00 ......................... 00 ............... 0000 .. 00 .... 000 ......... 36A Appendix A 7 - SPECIAL DRAWINGS (BEARING FITS) Pull down First Intermediate and Shipper Shaft 0000 00 00000000 00000000 000000 0000 00000000 0000 oo• 39A Pull down Input Shaft 00000000 .... 00 ........... 00 ................ 00 .. 0000000000000000 ..... 00 .. 000000 .... 00 .. 000.000 oo• ............ 00 ....... 39A Pull down Second Intermediate Shaft 0000 oo0000oo0000 00 00 000 000 ooooooooooooooo 00 00 39A Rotary Gearcase Shafts 00 0000 00.0000 000 00.00 00 00 00 00 oo 00 00 ooO 00 40A Lower Guide Rollers 00 000000 000 00 00 00 0000 00 000000 41A Upper Guide Rollers and Shipper Shafts 0000 ........ 00 .... 00 .. 0000 .. 0000 .. 000000000000 0000000000000000 0000 ................ 00 .. 41A (
CHAPTER I MECHANICAL MAINTENANCE SECTION 1 -MAINTENANCE PROCEDURE
GENERAL
This section ofthe manual describes those aspects of preventive maintenance such as scheduled reports and safety precautions as they pertain to the 49-R 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 apartofthemine'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.
Each problem should be thoroughly reviewed and evaluated before scheduling any maintenance or repair. The following points should be considered during the evaluation.
1. Is the problem one of normal wear?
2. Is the problem caused by machine application?
3. Is the problem a result of operator error?
4. Is the problem a result of unavoidable circumstances?
5. Is the problem of a repetitive nature?
6. By leaving the repairs to a later date, will any other component be affected?
7. Can repairs be accomplished immediately?
8. Will the cost of repairs immediately rather than later be worthwhile?
9. How long will the machine be down?
Once maintenance or repair has been scheduled, take the following points into consideration to minimize downtime and expense.
1. Are all tools and equipment needed to accomplish maintenance or repair available on the job, and are they in good repair?
2. Are all replacement parts on hand and readily available?
3. Is replacement of auxiliary parts, such as seals and bearings, necessary to accomplish repair, and have they been ordered?
4. Is all disassembly and reassembly data available?
5. Have repair crews been scheduled?
6. Will there be adequate supervision on hand for the repair crews?
7. Has the manufacturer been consulted for Service or Engineering assistance?
8. How long will the machine be down?
Once repair has been accomplished, the problem should again be reviewed with the following things in mind.
1. Was the cause of the problem permanently corrected or just patched?
2. What guarantee is there the same problem will not occur again?
BI379581
© BUCYRUS-ERIE COMPANY, 1987 1
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