CAT Bucyrus 49-RIII Blast Hole Drill Mechanical Maintenance Manual BI115938 - PDF DOWNLOAD by www.heydownloads.com

The purpose of this manual is to provide information concerning the general maintenance of the 49-RIII Rotary Blast Hole Drill.

The Model 49-RIII 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 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 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 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 conseq!lences of each method. It is therefore extremely important that anyone who uses a service procedure or tool which is not recommended by Bucyrus 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, 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 _____________________

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FOREWORD

BI115938

BUCYRUS INTERNATIONAL, INC. General Offices: South Milwaukee, Wisconsin, U.S.A.

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PAGE CHAPTER 1 MECHANICAL

SECTION 1 - MAINTENANCE PROCEDURE .......................................................................... 1-1-1 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 ...................................................................................................... 1-2·1 Crawler Belts ....................................................................................................................... 1-2-1 Adjustment .................................................................................................................. 1-2-2 Link Replacement 1-2-3 Belt Replacement 1-2-3 Lower Rollers 1-2-4 Repair 1-2-4 Upper Rollers ....................................................................................................................... 1-2-5 Repair 1-2-5 Take-Up Tumblers .............................................................................................................. 1-2-6 Repair ........................................................................................................................... 1-2-6 ( Drive Tumbler ..................................................................................................................... 1-2-7 Repair 1-2-7 Planetary Gearbox .............................................................................................................. 1-2-8 Crawler Frames 1-2-10 Repair , 1-2-10 Axles 1-2-12 Repair 1-2-12 SECTION 3 - MAINFRAME ........................................................................................................... 1·3·1 Mainframe ............................................................'................................................................ 1-3-1 Repair ........................................................................................................................... 1-3-1 Bit Viewing Hatch 1-3-1 Repair 1-3-2 Mast A-Frame : 1-3-2 Repair ................................................................................................................:.......... 1-3-2 Leveling Jacks 1-3-2 Repair 1-3-4 Machinery House ................................................................................................................. 1-3-6 Repair ........................................................................................................................... 1-3-6 House Ventilation Fan and Filter 1-3-6 Walkways and Ladders ; 1-3-8 Operator's Cab ..................................................................................................................... 1-3-9 Operator's Seat 1-3-9 Operator's Controls 1-3-9 Air Conditioning 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 BI115938

TABLE OF CONTENTS

MAINTENANCE

CHAPTER 2 SYSTEM

Hydraulic Maintenance .......................................................................................... 1-3-17 (" Repair ......................................................................................................................... 1-3-17 \ SECTION 4 - MAST ............................................................................................................,.......·....... 1·4·1 Mast Structure 1-4-1 Repair ........................................................................................................................... 1-4-1 Mast Safety Slings ............................................................................................................. 1-4-2 Repair 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 (Optional) 1-4-9 Repair ........................................................................................................................... 1-4-9 Rotary Shock Coupling .................................................................................................... 1-4-10 Repair 1-4-10 Rotary Shock Coupling 1-4-11 Repair ; 1-4-12 Rotary/Pulldown Guide Frame 1-4-13 Guide Roller Adjustment ....................................................................................... 1-4-13 Repair ......................................................................................................................... 1-4-13 Pulldown Gearcase ........................................................................................................... 1-4-17 Repair 1-4-17 Hoist Brake ........................................................................................................................ 1-4-22 Inspection 1-4-22 Brake Wear Adjustment 1-4-23 Replacement of Friction Discs 1-4-23 (Disassembly of Magnet Body and Armature 1-4-24 Reassembly of Magnet Body and Armature 1-4-24 Pipe Racks " 1-4-25 Repair ................:........................................................................................................ 1-4-25 Tool Wrenches ........;.......................................................................................................... 1-4-28 Repair ......................................................................................................................... 1-4-28 Breakout Wrench .............................................................................................................. 1-4-29 Repair ...........................................,............................................................................. 1-4-29 Adjustment 1-4-29 Auxiliary Winch 1-4-30 Mast Braces " 1-4-30 Repair " , 1-4-31 Adjustment ................................................................................................................ 1-4-31

SECTION 1 - SYSTEM OPERATION ........................................................................................... 2·1·1 Cylinder Circuit ; 2-1-1 Propel Circuit ; 2-1-1 SECTION 2 - GENERAL MAINTENANCE ............................................................................... 2-2-1 Hydraulic System Cleanliness 2-2-1 Oil Requirements ................................................................................................................ 2-2-1 Oil and Filter Changes , 2-2-1 Weekly Maintenance Checks 2-2-1 ( BI115938

HYDRAULIC

CHAPTER 4 DUST CONTROL

CHAPTER 5 LUBRICATION

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ROTARY SCREW COMPRESSOR (A-C COMPRESSOR CORP. KS-31-AC(X) OR KS-27-AC) 3-3-1 Description ........................................................................................................................... 3-3-1 Coupling Alignment 3-3-2 Parallel Misalignment .............................................................................................. 3-3-2 Angular Misalignment .............................................................................................. 3-3-3 Start-Up Procedure ............................................................................................................ 3-3-3 Shutdown 3-3-5 Controls and Instruments ................................................................................................. 3-3-5 Air Pressure Control System 3-3-5 Variable Volume Feature (Optional) 3-3-9 Lubrication System : 3-3-9 Compressor Oil System ......................................................................................... :.3-3-9 Lubrication - compressor ; 3-3-10 Lubricant Specifications 3-3-10 Filling Oil System (Initially) Oil Level Gauge ...................................................................................................... 3-3-10 Adding Oil Between Changes ............................................................................... 3-3-10 . Draining Oil System .............................................................................................. 3-3-12 Refilling Oil System ............................................................................................... 3-3-13 Compressor Oil Strainer and Filters 3-3-13 Compressor Oil Cooler : 3-3-13 Temperature Control Valve 3-3-14 Compressor Oil Separator Elements 3-3-15 Air Filters 3-3-16 Maintenance Schedule ............................................................................................ 3-3-18 Preventative maintenance 3-3-19 Intake Valve Service (figure 3-3-16) .................................................................. 3-3-19 Air End Input Shaft Oil Seal Replacement (figure 3-3-17) 3-3-21

SECTION 3 -

SECTION 1 - GENERAL MAINTENANCE ............................................................................... 4-1-1 Drilling Platforms and Dust Curtains 4-1-1 Filter/Clone® 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 System 4-1-2 Operation 4-1-2 Filling Water Tank ............................................................................................................. 4-1-3 Deck Washdown System (Optional) ............................................................................... 4-1-3 Operating Principle 4-2-1 SECTION 2 - MAINTENANCE OF FILTER/CLONE® (TIPTON) ...................................... 4-2-1 Maintenance 4-2-1

SECTION 1 . LUBRICATION PROCEDURES .......................................................................... 5-1-1 General .................................................................................................................................. 5-1-1 Lubricant Cleanliness 5-1-1 Lubrication Points .........................................................:..................................................... 5-1-1 Lubrication Benchmarks ................................................................................................... 5-1-8 BI115938

( Rear Jacks 2-2-2 Front Jack 2-2-2 Prestart Inspection 2-2-3 Hydraulic Systems Tests .................................................................................................. 2-2-3 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 ......................................................... 2-2-8 Dust Curtain Cylinders ........................................................................................... 2-2-8 Dust Seal Slider 2-2-8 Mast Lock 2-2-8 Mast Brace Lock Cylinders 2-2-8 A-Frame Lock' Cylinders 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 2-2-9 Mast Raise/Lower 2-2-9 Auxiliary Winch 2-2-9 Hydraulic Central Lube Drive Pressure Check ............................................... 2-2-10 Window Guard Function Check ........................................................................... 2-2-10 Water Injection Drain Valves Check .................................................................. 2-2-10 Water Injection Pump Function Check .............................................................. 2-2-11 Water Injection Washdown Check Check Jacks in Auto Level Mode , 2-2-12 Pipe Rack Position Check 2-2-13 Pcipe Rack Lock and Gate Cylinder Port Relief Setting ................................ 2-2-13 Pipe Thread Lubricator Check ............................................................................. 2-2-13 Pipe Positioner Function Check ........................................................................... 2-2-13 Center Guide Function Check plus Constant Pressure Check 2-2-13 Automatic breakout wrench check 2-2-14 CHAPTER 3 AIR SYSTEM SECTION 1- SYSTEM OPERATION' ........................................................................................... 3-1-1 Main Air System ................................................................................................................. 3-1-1 SECTION 2 - GENERAL MAINTENANCE ............................................................................... 3·2·1 Main Air System ................................................................................................................. 3-2-1 General 3-2-1 Intake Air Filter ................................................................................................................. 3-2-1 ( Filter Replacement ..................................................................................................... 3-2-1 Compressor Radiator ............................................................. :............................................ 3-2-2 BI115938

SECTION 2 - LINCOLN AUTOMATIC SYSTEM ..................................................................... 5-2-1 ( Troubleshooting Systems 5-2-1 Air Locks ..................................................................................................................... 5-2-1 Dirty Supply Lines 5-2-1 All Injectors Do Not Work Properly 5-2-1 After Venting, The Indicator Stems on the Injectors do not Return to Their Normal Position ............................................................................................. 5-2-1 Graco Pump Servicing 5-2-2 .' Pressure Relief Procedure ....................................................................................... 5-2-2 Replacing the Throat Seals .................................................................................... 5-2-2 Disconnecting the Reciprocator and Displacement Pump 5-2-2 Lubrication 5-2-10 APPENDIX Al . GEAR INSPECTION .......................................................................................... lA-1 General lA-1 APPENDIX A2 - BOLT TORQUING ............................................................................................. 2A·I Torque Wrench Method ................:..................................................................................... 2A-1 Turn Of The Nut Method 2A-2 APPENDIX A3 - PINION, BRAKE DRUM AND COUPLING INSTALLATION .••.•••••••• 3A-l Removal From Shaft ........................................................................................................... 3A-I Mounting On Shaft 3A-1 APPENDIX A4 . LUBE BENCHMARKS ...................................................................................... 4A-l MPG - Multi-Purpose Type Grease 4A-1 Scope 4A-1 Application 4A-1 General Requirements 4A-1 Compounding ............................................................................................................... 4A-1 ( Specific Requirements ............................................................................................... 4A-1 Notations ...................................................................................................................... 4A-1 Air Compressor (Screw Type) Lubricant ........................................................................ 4A-2 DPTL - Drill Pipe Thread Lubricant 4A-2 Scope 4A-2 Application 4A-2 General Requirements . Specific Requirements ............................................................................................... 4A-2 MPO - Milti-Purpose Oil .................................................................................................... 4A-3 Scope 4A-3 Application 4A-3 General Requirements 4A-3 Viscosity Recommendations ...................................................................................... 4A-3 OGL - Open Gear Lubricant ............................................................................................ 4A-3 Scope 4A-3 Application 4A-3 Methods of Application ............................................................................................. 4A-3 General Requirements 4A-3 Type of Lubricants ..................................................................................................... 4A-4 Compounding ............................................................................................................... 4A-4 Specific Requirements for all Types of Lubricants ............................................ 4A-4 RGL - Regular Type Gear Lubricant 4A-5 Scope ............................................................................................................................. 4A-5 ( Application 4A-5 General Requirements 4A-5 Compounding ............................................................................................................... 4A-5 Viscosity and Viscosity Index .................................................................................. 4A-5 BI115938

Notations ( Rotary Blast Hole Drills .......................................... ............................................... 4A-6 Notations ...................................................................................................................... 4A-7 RWRL - Running Wire Rope Lubricant 4A-8 Scope .........................................................................................;................................... 4A-8 Application ................................................................................................................... 4A-8 General Requirements : 4A-8 Compounding 4A-8 Special Requirements ................................................................................................ 4A-8 HYDO - Hydraulic Oil ....................................................................................................... 4A-9 PAO Synthetic Hydraulic Fluid 4A-9 Parafinnic base Petroleum Hydraulic Fluid .4A-IO APPENDIX A5 - RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRINCIPAL STRUCTURES ON BLAST HOLE DRILLS ........................... 5A·1 APPENDIX A6 . PREVENTIVE MAINTENANCE CHECK LIST ........................................ 6A·1 APPENDIX A 7 IIIfi SPECIAL FITS .................................................................................................... 7A·1 APPENDIX AS . AERO QUIP ORS CONNECTIONS ............................................................... SA·1 ( BI115938

SAFETY GENERAL

The importance of overall safety in the maintenance of mining equipment should always be emphasized; excavating operations should always be emphasized; excavating operations may involve a variety of hazardous conditions. Many critical components are subject to wear and other deterioration which limits their useful life; thus they are expendable. When new, all such parts have a built-in reserve strength against unknown factors and reasonable loss of durability from gradual wear. If, however, inspection and adjustment are neglected, these parts eventually reach a condition where they become a safety problem. Similarly, failure to replace various mechanisms to insure proper performance of the machine also constitutes a safety problem. Study this manual carefully and follow all recommended procedures to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of these procedures. Supervisor, operators and maintenance men should continuously follow !;Iafe practices.

IN-OPERATION MAINTENANCE

operator's hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.

A repair or maintenance job on equipment is not complete until guards, plates and other safety devices have been replaced before the equipment is restored to operation.

PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK

The operator must be sure the equipment is in a safe position before repairs or adjustments are made. The machine should not be endangered by falling rock or a yielding support surface. Before beginning repair or adjustment, the operator shall:

• Secure the rotary drive unit and tool string.

• Set all brakes.

• De-energize control functions and tag.

• Do whatever else is necessary to prevent accidental movement of the machine.

NOTE: If power is essential to the repair, it should only be energized when all personnel are clear of electrical and mechani-

-------S3:fety hazards. The power should only be enin active service be inspected at regular inter- ergized during the required period and not vals for proper adjustment of operating mecha- when repair work is being done. nisms, excessive wear of components, system cleanliness and any other defects. In-operation deficiencies should be carefully investigated. It should be determined if a safety problem exists. Remember, maintenance is vital to safe operation. It should be performed systematically by competent personnel.

From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely accomplished while the machine is running. Obviously, there are some maintenance procedures, such as gear tooth inspection and replacement, which require machine shut down. However, many support duties can be safely and effectively handled at shift change when the machine is still activated.

Automatic lubrication systems function throughout the operation cycles of the machine. These systems release premeasured lubricant which lengthen the wear life of the machinery units. Other parts of the machinery may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the

Prior to undertaking any work, maintenance personnel should notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the starting controls should be locked in the "off' position and tagged. The lock and tag should be removed only by the maintenance people who installed them. During all phases of maintenance, use extreme caution when working near electrical equipment. N ever work near exposed, energized high voltage connections.

Approved protection· equipment such as gloves and insulated hooks or tongs should always be used when high voltage electrical cables are handled. Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers, and switches. While performing maintenance, the awkward positions assumed often increase injuries due to handling heavy parts. As a precautionary measure, use mechanical handling equipment whenever possible. The mining foreman can facilitate safer and easier maintenance work by providing blocking materials. Service crews should have a

1-1-2

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fundamental knowledge of lifting practices so their knees and legs are used rather than their backs.

ACAUTION: Many of the components of the 49-RIII drill are heavy, bulky items. Extreme caution should be used when lifting. Personnel should be certain of the weights of components before attempting to lift them, either manually or with some lifting device. Follow all applicable safety rules when using cranes or other lifting equipment. Be sure of the load, lifting height and radius, and capacity of the lifting device before lifting. Failure to fol-

low all applicable safety rules when lifting can cause serious or fatal injury to personnel.

ACAUTION: When removing certain machine parts for maintenance or replacement purposes, it may be a practice to loosen these parts by striking them with a sledgehammer. Use extreme caution when striking metal parts as chips may fly off with great force and possibly cause serious injury. Wear adequate protective clothing including a face shield. Alternate methods of removal might involve using a soft metal hammer or a hydraulic jack with applicable fixtures.

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1-1-3 (1-1-4 Blank) BI115938

CHAPTER 1

MECHANICAL MAINTENANCE

SECTION 2 - LOWER WORKS

CRAWLER BELTS

The crawler belts should be inspected frequently· to prevent an unexpected breakdown (figure 12-1).

Check the links for cracks, worn lugs, elongated link pin bores and other damage. Minor cracks in the link do not constitute a major problem. However, cracked links should be repaired by

1. RH CRAWLER FRAME 7.

welding or replaced at a convenient time. Links with broken or worn drive lugs should be replaced at the earliest convenient time as they can cause the belt to ride off the rollers or takeup tumblers. Links with elongated pin bores should be checked carefully for cracks at the pin lugs and replaced if badly worn or cracked. Bent, broken, or badly worn link pins should be replaced.

ROLLER BUSHING 18. AXLE RETAINER ROLLER SHAFT 19. RETAINER SHIM

TAKE-UP TUMBLER

20. RETAINER FAI3REEKA PAD TUMBLER BUSHING 21. MOUNTING BLOCK TUMBLER SHAFT 22. BLOCKFABREEKAPAD

FABREEKA WASHER

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11.

12. 13. 14. 15 15. 16. 17. y27

2. LH CRAWLER FRAME 8. 3. UPPER ROLLER 9. 4. ROLLER BUSHING 10. 5. ROLLER SHAFT

6. LOWER ROLLER

SHAFT

23.

SUPPORT SHIMS 24.

25.

DRIVE TUMBLER

REAR AXLE 27.

PIN AXLE SPACER 28.

LINK

SUPPORT

EQUALIZER AXLE PLANETARY GEARBOX

CENTER PIN

26. BEARING BLOCK

END

CRAWLER

29. LINK

30. PIN RETAINER

1-2-1 BI115938

FIGURE 1-2-1

ADJUSTMENT

To determine if the crawler belts should be adjusted, raise the machine up onthe leveling jacks so that the crawler belts are hanging free and not contacting the ground. At the center of the crawler frame measure the clearance between the bottom of the crawler frame and the roller surface of the crawler links (figure 1-2-2). The minimum clearance is 9" and the maximum clearance is 14". When the maximum clearance is reached, the crawler belts must be adjusted to 9" to 11". Do not operate machine with belt slack in excess of maximum clearance.

Adjustment of the crawler belts is accomplished at the take-up tumbler of the belts. The take-up tumblers are mounted on shafts which are mounted in supports which in turn ride in slots in the crawler frames. Shims place ahead or behind the supports position the tumbler to provide the desired belt tension (figure 1-2-3).

To adjust belt tension:

1. Using the leveling jacks, raise the machine until the crawlers and belts are suspended above the ground. Block the machine in this position.

2. Remove the tumbler shim guards from the inside and outside of the crawler frame.

3. Position suitable hydraulic jacks, (20-ton) supplied with the machine, behind each of the supports.

4. Remove several shims from behind the supports.

5. Actuate the hydraulic jacks to push the supports rearward to provide the desired belt tension. Make sure the supports slide straight in the·crawler frame and do not become cocked.

CRAWLER BELT SAG FIGURE 1-2-2

1-2-2 9"

2 1 2 3 4

MIN. TO 14" MAX.

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1. TUMBLER SHAFT SUPPORT 2. SHIMS 3. HYDRAULIC JACK 4. HYDRAULIC HOSE AND FITTINGS 5. HYDRAULIC PUMP 6. CRAWLER BELT.

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CRAWLER BELT ADJUSTMENT FIGURE 1-2-3

LINK REPLACEMENT

FIGURE 1-2-4

6. Insert sufficient shims in front of the supports to maintain the adjustment. Several different thicknesses of shims are provided. Be sure that the shims are the same thickness behind each support.

7. Remove the hydraulic jacks.

8. Reinstall the shim guards on the crawler frame.

9. Repeat the procedure for the other crawler belt if necessary.

10. Remove blocking and lower machine. LINK REPLACEMENT (figure 1-2-4)

To replace a link in the crawler belts:

1. Propel the machine to position the defective link in an accessible position near one end of the crawler.

2. Remove the tension from the belt by removing all of the tensioning shims from behind the take-up tumbler supports. Refer to the CRAWLER BELT ADJUSTMENT for details of this procedure.

3. Secure the belt against unwanted movement.

4. Attach a suitable lifting device to the defective link. Part the belt at the defective link by removing the two link pins securing the link to one end of the belt.

5. With the lifting device, lower the end of the crawler belt with the defective link to the ground.

6. Remove the defective link from the belt.

7. Install the replacement link on the end of the belt resting on the ground.

8. Using the lifting device, lift the end of the belt into position to insert the remaining link pins.

9. Insert the link pins and secure with cotter pins.

10. Remove any equipment securing the belt against movement.

11. Readjust belt tension as described in the CRAWLER BELT ADJUSTMENT topic of this manual.

BELT REPLACEMENT (figure 1-2-5)

Although belt replacement is required infrequently, there are times when it is necessary. To replace a belt, first propel the machine to firm, flat, level ground.

1. Remove tension from the belt by removing the shims from behind the take-up tumbler supports as described in the topic CRAWLER BELT ADJUSTMENT.

2. Part the belt at the midway point of the upper slide by removing the link pins.

3. Attach a suitable lifting device to the ends of the belt and drag and lift each end of the belt off the crawler frame and lay it on the ground.

4. Using the machine leveling jacks, raise the machine sufficiently to allow the old belt to be dragged from underneath of the crawler frame. Securely block the machine in this position.

5. Using a suitable vehicle and rigging, drag the old belt from underneath of the crawler frame.

6. Assemble the new belt and lay it flat on the ground near the crawler frame.

7. Using a suitable vehicle and rigging, drag the new belt underneath of the crawler frame so that the roller path in the center of the belt is aligned with the lower rollers, drive tumbler and take-up tumbler.

8. Remove the blocking and slowly lower the machine until the crawler rollers and tumblers are resting on the belt.

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1-2-3 \ BI115938

SEPARATE MIDWAY BETWEEN DRIVE TUMBLER AND TAKE-UP TUMBLER

9. Using a suitable lifting device, lift the ends of the belt into a position to insert the link pins.

10. Insert the link pins and cotter pins to complete the belt.

11. Readjust the belt tension as described in the topic CRAWLER BELT ADJUSTMENT.

LOWER ROLLERS

Inspect the lower rollers for cracks and damage that can impair normal tracking of the crawler belts (figure 1-2-6).

Once a month raise the machine with the leveling jacks to allow inspection of the rollers. Block the machine in a raised position. Using a suitable lever, check the clearance ofthe roller bushing by lifting and then lowering the roller. Replace the bushing if the clearance is excessive.

REPAIR

The most common problem encountered with lower rollers is bushing wear. However, over a period of time, the rollers will wear and possibly develop cracks. The cracks may be repaired by gouging and welding. Follow the welding instructions in the APPENDIX.

If bushing replacement is necessary, the roller must be removed from the machine. To accomplish this:

1. Relieve the crawler belt tension as described in the topic CRAWLER BELT· REPLACEMENT.

2. Using the machine leveling jacks, raise the machine sufficiently to allow removal of the roller. Block the machine in the raised position: It may be necessary to jack the crawler belt away from the crawler frame and block in position to remove the extreme front or rear rollers.

3. Remove lubrication guards and lube lines of so equipped to gain access to the roller shaft.

4. Remove the capscrew and retainer securing the lower roller shaft to the crawler frame.

9 6

1. DRIVE TUMBLER 4. UPPER ROLLER 7. REAR AXLE 2. TAKE-UP TUMBLER 5. PLANETARY GEARBOX 8. FRONT AXLE 3. LOWER ROLLER 6. CRAWLER FRAME 9. CRAWLER BELT CRAWLER BELT REPLACEMENT FIGURE 1-2-5

/--.,

1-2-4

1. LOWE;R ROLLER 4. SHAFT RETAINER 2. ROLLER BUSHING 5. RETAINER CAPSCREW