FOREWORD
is provide of Blast Hole Drill.
The purpose of this manual is to provide information concerning the general maintenance of the 49-RII Rotary Blast Hole Drill.
The Model 49-RII consists of three major units, the lower works, the mainframe and the mast. The lower works provides a foundation for the mainframe and contains the necessary equipment to propel the drill. The mainframe includes the hydraulic system, main air system, and the machinery house. The machinery house encloses the majority of the mechanical equipment necessary for the main air system, the hydraulic systems and electrical control systems. The machinery house is pressurized with filtered air to minimize dirt and heat build-up. The operator's cab, mounted to the mainframe, includes the operator's station, and encloses the majority of the controls necessary to operate the drill. The mast contains the drill pipe and drilling tools, the pipe racks, and the rotary and pulldown machinery.
The of major the mast. The lower works provides a foundation the necessary the main air and machinery encloses the majority of the equipment necessary system, systems. machinery house is filtered to dirt heat The mounted to the operator's encloses majority of the operate the drill. The contains the drill pipe and drilling tools, the pipe racks, and the machinery.
This manual consists of six chapters, each divided into sections. A table of contents is located in the front of the manual.
This manual consists of six chapters, each divided into sections. table of contents is located in the front the
manual the words
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 appear bold type. CAUTION is the alert and indicates that injury to could if proper procedures during operation maintenance. Always CAUTION note and use extreme care while that particular function. a possible machine components if proper procedures are word should be prevent damage.
NOTE is or to additional concerning being
NOTE is used to stress a point or to give additional information concerning the procedure being discussed.
These and WARNING's not all-inclusive. is impossible for Bucyrus-Erie panyto know, and advise maintenance and service personnel in conceivable a operation might be performed of resulting possible consequences It is extremely uses tool not to first satisfy that the service procedure tool chooses own or cause or component
These CAUTION's and WARNING's are not all-inclusive. It is impossible for Bucyrus-Erie Companyto know, evaluate, and advise maintenance and service personnel in every conceivable way a service operation might be performed and of the resulting possible hazardous consequences of each method. It is therefore extremely important that anyone who uses a service procedure or tool which is not recommended by Bucyrus-Erie Company to first satisfy himself that the service procedure or tool he chooses will not jeopardize his· own safety, the safety of others, or cause machine or 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
effort has been made to make this manual as complete and accurate as at the time of publication. Bucyrus-Erie Company, however, reserves the right continually improve its products. For this reason have been made to the machine or its that are' not detailed in this MACHINE
BUCYRUS-ERIE COMPANY
BUCYRUS-ERIE COMPANY
General Offices: South Milwaukee, Wisconsin, U.S.A. LlT S381 1291
General Offices: South Milwaukee, Wisconsin, U.S.A. S381 1291
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PAGE CHAPTER 1 MECHANICAL MAINTENANCE SECTION 1- MAINTENANCE PROCEDURE General 1-1-1 Maintenance Schedules and Reports 1-1-1 Safety 1-1-2 General 1-1-2 In-operation Maintenance 1-1-2 Precautions Before and During Maintenance Work 1-1-2 SECTION 2- LOWER WORKS Crawler Belts 1-2-1 Adjustment 1-2-1 Link Replacement 1-2-4 Belt Replacement 1-2-5 Lower Rollers 1-2-6 Upper Rollers 1-2-7 Take-up Tumblers 1-2-7 Drive Tumbler 1-2-8 Planetary Gearbox 1-2-9 Crawler Frames 1-2-12 Axles 1-2-13 SECTION 3- MAINFRAME Mainframe 1-3-1 Bit viewing Hatch 1-3-1 Mast A-Frame 1-3-2 Leveling Jacks ,, 1-3-2 Machinery House ; 1-3-6 House Ventilation Fan and Filter 1-3-6 Walkways and Ladders : 1-3-6 Operator's Cab ; 1-3-8 Operator's Seat 1-3-8 Operator's Controls 1-3-9 Ventilation Unit 1-3-9 Hydraulic Pump Drive 1-3-9 Cable Reel 1-3-11 Level Wind Drive Adjustment 1-3-11 Hydraulic Adjustments 1-3-14 Lubrication 1-3-17 Hydraulic Maintenance 1-3-17 Repair 1-3-17 SECTION 4- MAST Mast Structure 1-4-1 Mast Safety Slings 1-4-2 Rotary Gearcase 1-4-2 Drive Shaft Adjustment 1-4-3 Repair 1-4-3 Rotary Motor 1-4-8 Rotary Coupling 1-4-9 Rotary Shock Sub (for machines 140916 thru 140976) 1-4-10 Rotary Shock Sub (for machines 140977 and future) 1-4-11 CHAPTER 1 MAINTENANCE 1- MAINTENANCE General Schedules 1-1-1 Safety 1-1-2 In-operation Maintenance Work 1-1-2 SECTION 2- LOWER 1-2-1 Adjustment 1-2-4 Belt 1-2-6 Crawler Frames 1-2-12 Axles 1-2-13 1-3-1 Jacks Machinery House 1-3-6 and 1-3-6 Cab 1-3-8 Controls 1-3-9 Ventilation 1-3-9 Hydraulic Pump Drive 1-3-9 Cable 1-3-11 Drive Adjustment 1-3-11 Adjustments 1-3-14 1-3-17 1-3-17 SECTION MAST Structure 1-4-1 Safety Slings 1-4-2 Gearcase Drive Adjustment 1-4-3 Coupling thru Sub BI005490
TABLE OF CONTENTS
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CHAPTER 2 HYDRAULIC SYSTEM
Rotary/Pulldown Guide Frame 1-4-12 Guide Roller Adjustment 1-4-12 Repair 1-4-16 Pull down Gearcase 1-4-17 Hoist Brake 1-4-21 Inspection 1-4-21 Brake Wear Adjustment 1-4-21 Replacement of Friction Discs 1-4-22 Disassembly of Magnet Body and Armature 1-4-22 Reassembly of Magnet Body and Armature 1-4-22 Pipe Racks 1-4-23 Tool Wrenches 1-4-24 Casing Tong Jib Crane 1-4-26 Pipe Positioner 1-4-28 Auxiliary Winch 1-4-28 Mast Braces 1-4-30 Repair 1-4-30 Adjustment 1-4-30
SECTION 1- SYSTEM OPERATION Cylinder Circuit Hydraulic System 2-1-1 Propel Circuit Hydraulic System 2-1-1 SECTION 2- GENERAL MAINTENANCE Hydraulic System Cleanliness 2-2-1 Oil Requirements 2-2-1 Oil and Filter Changes 2-2-1 Filter Maintenance 2-2-1 Weekly Maintenance Checks 2-2-2 Oil Reservoir Repairs 2-2-2 Leveling Jack Counterbalance Valve Pressure Relieving Procedure 2-2-2 Rear Jacks 2-2-2 Front Jack 2-2-3 Prestart Inspection 2-2-3 Hydraulic Systems Tests 2-2-4 Propel Pump Charge Pressure Check 2-2-4 Control Pressure Check 2-2-4 Propel Enable Valve and Low Speed Select Check 2-2-4 Jack Cylinder Check in Manual Mode 2-2-5 Flow Control Check 2-2-5 Jack Cylinder Drift Test 2-2-6 Brake Release Pressure Check 2-2-6 Propel Brake Emergency Release Check 2-2-6 Propel Pump Main Relief Pressure Check 2-2-7 Crawler Function Check 2-2-7 Bit Viewing Hatch Check 2-2-7 Boarding Stair Check 2-2-7 Main Flow Valve Check 2-2-7 Breakout Wrench and Tool Wrench Check 2-2-7 Dust Curtain Cylinders 2-2-8 Dust Seal Slider 2-2-8 Mast Lock (Station 6 of 7-station manifold) 2-2-8 Mast Brace Lock Cylinders (Station 4 of 7-station manifold) 2-2-8 Rotary/Pulldown Guide Frame 1-4-12 Guide Roller Adjustment 1-4-12 Repair 1-4-16 Pull down Gearcase 1-4-17 Hoist Brake 1-4-21 Inspection 1-4-21 Brake Wear Adjustment 1-4-21 Replacement of Friction Discs 1-4-22 Disassembly of Magnet Body and Armature 1-4-22 Reassembly of Magnet Body Armature 1-4-22 Pipe Racks 1-4-23 Tool Wrenches 1-4-24 Casing Tong Jib Crane 1-4-26 Pipe Positioner 1-4-28 Auxiliary Winch 1-4-28 Mast Braces 1-4-30 Repair 1-4-30 Adjustment 1-4-30 CHAPTER 2 HYDRAULIC SECTION 1- OPERATION Cylinder Circuit Hydraulic 2-1-1 Propel Circuit Hydraulic System 2-1-1 SECTION 2- GENERAL MAINTENANCE Hydraulic System Cleanliness 2-2-1 Oil Requirements 2-2-1 Oil and Changes 2-2-1 Filter Maintenance 2-2-1 Weekly Maintenance Checks 2-2-2 Oil Reservoir Repairs 2-2-2 Leveling Jack Counterbalance Valve Pressure Relieving Procedure 2-2-2 Rear 2-2-2 Front Jack 2-2-3 Prestart Inspection 2-2-3 Hydraulic Systems Tests 2-2-4 Propel Pump Charge Pressure 2-2-4 Control Pressure Check 2-2-4 Propel Enable Valve and Low Speed 2-2-4 Jack Cylinder Check in Manual Mode 2-2-5 Flow Control Check 2-2-5 Jack Cylinder Drift Test 2-2-6 Brake Release Pressure Check 2-2-6 Propel Brake Emergency Release Check 2-2-6 Propel Pump Main Relief Pressure Check 2-2-7 Crawler Function Check 2-2-7 Bit Viewing Hatch Check 2-2-7 Boarding Stair Check 2-2-7 Main Flow Valve Check 2-2-7 Breakout Wrench and Tool Wrench Check 2-2-7 Dust Curtain Cylinders 2-2-8 Dust Seal Slider 2-2-8 Mast Lock (Station 6 of 7-station manifold) 2-2-8 Mast Brace Lock Cylinders (Station 4 of 7 -station manifold) 2-2-8 BI005490
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CHAPTER 3 AIR SYSTEM
CHAPTER 3 AIR
A-Frame Lock Cylinders (Station 5 of 7-Station Manifold) 2-2-8 Mast Lock Constant Pressure Check 2-2-8 Mast Brace Constant Pressure Check 2-2-8 A-Frame Lock Constant Pressure Check 2-2-8 Mast Raise/Lower 2-2-9 Auxiliary Winch 2-2-9 Hydraulic Central Lube Drive Pressure Check 2-2-10 Window Guard Function Check (Station 1 of 4-Station Manifold) 2-2-10 Water Injection Drain Valves Check (Station 1 of 5-Station Manifold) 2-2-10 Water Injection Pump Function Check 2-2-10 Water Injection Washdown Check (Station 3 of 4-Station Manifold) 2-2-11 Check Jacks in Auto Level Mode 2-2-12 Pipe Rack Position Check 2-2-12 Pipe Rack Lock and Gate Cylinder Port Relief Setting 2-2-12 Pipe Thread Lubricator Check 2-2-13 Pipe Positioner Function Check 2-2-13 Center Guide Functon Check plus Constant Pressure Check 2-2-13 Test Point Locations (for machines thru 141001) 2-2-15 Test Point Locations (for machines 141003 and up) 2-2-16
SECTION 1- SYSTEM OPERATION Main Air System 3-1-1 SECTION 2- GENERAL MAINTENANCE Main Air System 3-2-1 Intake Air Filter 3-2-1 Filter Replacement 3-2-1 Compressor Radiator 3-2-2 SECTION 3- ROTARY SCREW COMPRESSOR (A·C Compressor Corp. KS-31-LU, KS-27-LU, KS-31-AC or KS-27-AC) Description 3-3-1 Coupling Alignment 3-3-2 Parallel Misalignment 3-3-3 Angular Misalignment 3-3-3 Start-Up Procedure 3-3-3 Shutdown 3-3-4 Controls and Instruments 3-3-4 Air Pressure Control System 3·3-4 Reduced Unloaded Horsepower Feature (LU Design Compressor Only). 3·3-1O Variable Volume Feature (Optional) 3-3-13 Lubrication System 3-3-15 Compressor Oil System 3-3-15 Lubricant Specifications (LU Design Compressors) 3-3-15 Lubricant Specifications (AC Design Compressors) 3-3-15 Filling Oil System (Initially) 3·3-16 Oil Level Gauge 3·3-16 Adding Oil Between Changes 3-3-16 Oil Change Intervals 3-3-16 Draining Oil System 3-3-16 Refilling Oil System 3-3-17 Compressor Oil Strainer and Filters 3-3-17 Compressor Oil Cooler 3·3-17 Thermostatic Control Valve 3-3-17 Compressor Oil Separator Elements 3-3-19 A-Frame Lock Cylinders (Station 5 of 7-Station Manifold) 2-2-8 Mast Lock Constant Pressure Check 2-2-8 Mast Brace Constant Pressure Check 2-2-8 A-Frame Lock Constant Pressure Check 2-2-8 Mast Raise/Lower 2-2-9 Auxiliary Winch 2-2-9 Hydraulic Central Lube Drive Pressure Check 2-2-10 Window Guard Function Check (Station 1 of 4-Station Manifold) 2-2-10 Water Injection Drain Valves Check (Station 1 of 5-Station Manifold) 2-2-10 Water Injection Pump Function Check 2-2-10 Water Injection Washdown Check (Station 3 of 4-Station Manifold) 2-2-11 Check Jacks in Auto 2-2-12 Pipe Rack Position Check 2-2-12 Pipe Rack Lock and Gate Cylinder Port Relief Setting 2-2-12 Pipe Thread Lubricator Check 2-2-13 Pipe Positioner 2-2-13 Center Guide Functon Constant Pressure Check 2-2-13 Test Point Locations (for machines thru 141001) 2-2-15 Test Point (for 141003 and up) 2-2-16
SECTION 1- SYSTEM OPERATION Main Air System 3-1-1 SECTION 2- GENERAL Main Air System 3-2-1 Intake Air Filter 3-2-1 Filter Replacement 3-2-1 Compressor Radiator 3-2-2 SECTION 3- ROTARY SCREW COMPRESSOR (A·C Compressor Corp. KS-31-LU, KS-27-LU, KS-31-AC or KS-27-AC) Description 3-3-1 Coupling Alignment 3-3-2 Parallel Misalignment 3-3-3 Angular Misalignment 3-3-3 Start-Up Procedure 3-3-3 Shutdown 3-3-4 Controls and Instruments 3-3-4 Air Pressure Control System 3·3-4 Reduced Unloaded Horsepower Feature (LU Design Compressor Only). 3·3-1O Variable Volume Feature (Optional) 3-3-13 Lubrication System 3-3-15 Compressor Oil System 3-3-15 Lubricant Specifications (LU Design Compressors) 3-3-15 Lubricant Specifications (AC Design Compressors) 3-3-15 Filling Oil System (Initially) 3·3-16 Oil Level Gauge 3·3-16 Adding Oil Between Changes 3-3-16 Oil Change Intervals 3-3-16 Draining Oil System 3-3-16 Refilling Oil System 3-3-17 Compressor Oil Strainer and Filters 3-3-17 Compressor Oil Cooler 3·3-17 Thermostatic Control Valve 3-3-17 Compressor Oil Separator Elements 3-3-19 BI005490
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CHAPTER 4 DUST CONTROL
CHAPTER 4 DUST CONTROL
Cold Weather Start System (Option for LU Design Compressors) 3-3-19 Air Filters 3-3-20 Air Filter (Optional) 3-3-23 Maintenance Schedule 3-3-23 Intake Valve Service (for AC Design Units Only) 3-3-24 Air End input Shaft oil Seal Replacement (for AC Design Units Only) 3-3-26
SECTION 1- GENERAL MAINTENANCE Drilling Platforms and Dust Curtains 4-1-1 FILTERICLONE«l System (Tipton) 4-1-1 Daily Maintenance Checks 4-1-1 Monthly Maintenance Checks 4-1-1 Six Month Maintenance Checks 4-1-2 Water Injection 4-1-2 Operation (for machines 140916 thru 140962) 4-1-2 Operation (for machines 140963 thru 141001) 4-1-2 Daily Maintenance Check 4-1-3 Weekly Maintenance Check 4-1-3 Bimonthly Maintenance Checks 4-1-3 Fluid Levels 4-1-3 Shaft to Coupling Alignment 4-1-3 Flow Chart 4-1-4 Operation (for machines 141003 and up) 4-1-4 Filling Water Tank 4-1-4 Deck Washdown System 4-1-5 SECTION 2- MAINTENANCE OF FILTERICLONE«l (TIPTON) Operating Principle 4-2-1 Maintenance 4-2-1 CHAPTER 5 LUBRICATION SECTION 1- LUBRICATION PROCEDURES General 5-1-1 Lubricant Cleanliness 5-1-1 Lubrication Points 5-1-1 Lubrication Benchmarks 5-1-8 SECTION 2- LINCOLN AUTOMATIC SYSTEM Troubleshooting Systems 5-2-1 Air Locks 5-2-1 Dirty Supply Lines 5-2-1 All Injectors Do Not Function Properly 5-2-1 Mter Venting, the Indicator Sterns on the Injectors Do Not Return to their Normal Position 5-2-1 Failure of the Pump to Build Up Pressure (Lincoln Pump) 5-2-2 Slow Pressure Rise (Lincoln Pump) 5-2-2 Pump Operation (Lincoln Pump) 5-2-2 Pump Disassembly and Reassembly (Lincoln Pump) 5-2-2 Graco Pump Servicing 5-2-5 Pressure Relief Procedure 5-2-5 Replacing the Throat Seals 5-2-5 Disconnecting the Reciprocator and Displacement Pump 5-2-6 Lubrication 5-2-5 Cold Weather Start System (Option for LU Design Compressors) 3-3-19 Air Filters 3-3-20 Air Filter (Optional) 3-3-23 Maintenance Schedule 3-3-23 Intake Valve Service (for AC Design Units Only) 3-3-24 Air End input Shaft oil Seal Replacement (for AC Design Units Only) 3-3-26
SECTION 1- GENERAL MAINTENANCE Drilling Platforms and Dust Curtains 4-1-1 FILTERICLONE«l System (Tipton) 4-1-1 Daily Maintenance Checks 4-1-1 Monthly Maintenance Checks 4-1-1 Six Month Maintenance Checks 4-1-2 Water Injection 4-1-2 Operation (for machines 140916 thru 140962) 4-1-2 Operation (for machines 140963 thru 141001) 4-1-2 Daily Maintenance Check 4-1-3 Weekly Maintenance 4-1-3 Bimonthly 4-1-3 Fluid Levels 4-1-3 Shaft to Coupling Alignment 4-1-3 Flow Chart 4-1-4 (for and 4-1-4 Filling Water Tank 4-1-4 Deck Washdown System 4-1-5 SECTION 2- MAINTENANCE OF FILTERICLONE«l (TIPTON) Operating Principle 4-2-1 Maintenance 4-2-1
LUBRICATION SECTION 1- LUBRICATION PROCEDURES General 5-1-1 Lubricant Cleanliness 5-1-1 Lubrication Points 5-1-1 Lubrication Benchmarks 5-1-8 SECTION 2- LINCOLN AUTOMATIC SYSTEM Troubleshooting Systems 5-2-1 Air Locks 5-2-1 Dirty Supply Lines 5-2-1 All Injectors Do Not Function Properly 5-2-1 Mter Venting, the Indicator Sterns on the Injectors Do Not Return to their Normal Position 5-2-1 Failure of the Pump to Build Up Pressure (Lincoln Pump) 5-2-2 Slow Pressure Rise (Lincoln Pump) 5-2-2 Pump Operation (Lincoln Pump) 5-2-2 Pump Disassembly and Reassembly (Lincoln Pump) 5-2-2 Graco Pump Servicing 5-2-5 Pressure Relief Procedure 5-2-5 Replacing the Throat Seals 5-2-5 Disconnecting the Reciprocator and Displacement Pump 5-2-6 Lubrication 5-2-5 BI005490
CHAPTER 5
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