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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 pull down 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 consequences 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.
This section of the manual described those aspects of preventive maintenance such as scheduled reports and safety precautions as they pertain to the 49-RIII drill.
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.
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?
3. Is consultation with the manufacturer for design improvement necessary?
4. What costs were incurred in downtime, parts, tools and labor?
5. Could the problem have been prevented by prior action?
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 safe practices.
Safety requirements dictate that all machines in active service be inspected at regular intervals for proper adjustment of operating mechanisms, excessive wear of components, system cleanliness andany 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
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.
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 mechanical hazards. The power should only be energized during the required period and not when repair work is being done.
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. Never 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
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 lift· ing. 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 lift· ing device before lifting. Failure to fol·
low all applicable safety rules when lift· ing can cause serious or fatal injury to personnel.
ACAUTION: When removing certain mao chine parts for maintenance or replacement purposes, it may be a practice to loosen these parts by striking them with a sledge. hammer. Use extreme caution when strike ing 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.
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
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.
To determine if the crawler belts should be adjusted, raise the machine up on the 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.
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.
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.
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 of the roller bushing by lifting and then lowering the roller. Replace the bushing if the clearance is excessive.
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.
5. Support the lower roller with suitable blocking.
6. Remove the roller shaft.
7. Remove the blocking and lower the roller out of the crawler frame.
8. Inspect the roller bushing. Remove and replace the bushing if necessary.
9. Inspect the lower roller shaft. Replace if worn.
10. Inspect the crawler frame in the area of the lower roller. Repair shaft bore or thrust surfaces if necessary.
11. Lubricate the roller bushing and shaft.
12. Install roller in crawler frame and block in line with the shaft bore.
13. Insert roller shaft.
14. Install the retainer and capscrew to secure roller shaft to crawler frame. Remove the roller blocking.
15. Install lubrication guards and lube lines if so equipped.
16. Adjust lubrication guards and lube lines if so equipped.
17. Adjust belt tension as described in the topic CRAWLER BELT ADJUSTMENT.
18. Remove blocking and lower machine. Propel the machine to distribute the lubricant evenly in the roller and check roller operation.
Inspect the upper roller for cracks and damage that can impair normal tracking of the crawler belt (figure 1-2-6A).
Once a month use a jack to lift the crawler belt off the upper roller. With a suitable lever, check the clearance of the roller bushing by lifting and then lowering the roller. Replace the bushing if the clearance is excessive.
The most common problem encountered with upper rollers is bushing wear. However, over a period of time, the roller 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 ADJUSTMENT.
2. Using a jack, raise the crawler belt high enough so that the upper roller can be removed. Block the belt in this position.
3. Remove the capscrew and retainer securing the roller shaft to the crawler frame.
4. Support the roller with suitable blocking and remove the roller shaft.
5. Remove the roller and blocking from the crawler frame.
6. Inspect the roller bushing. Remove and replace the bushing if necessary.
7. Inspect the roller shaft. Replace if worn.
8. Inspect the crawler frame in the area of the upper roller. Repair shaft bore or thrust surfaces if necessary.
9. Lubricate the roller bushings and shaft.
UPPER ROLLER FIGURE 1-2-6A 4. SHAFT RETAINER 5. CRAWLER FRAME 5 1. UPPER ROLLER 2. ROLLER BUSHING 3. ROLLER SHAFT10. Install roller into the crawler frame and block in line with the shaft bore.
11. Install the roller shaft and secure the shaft with the retainer and capscrew. Remove the roller blocking.
12. Remove the crawler belt blocking.
13. Adjust belt tension as described in the topic CRAWLER BELT ADJUSTMENT.
14. Lubricate the roller. Propel the machine to distribute the lubricant evenly and check roller operation.
Inspect the take-up tumbler for cracks and damage that can impair normal tracking of the crawler belts (figure 1-2-7).
Every six months raise the machine with the leveling jacks to allow inspection of the tumblers. Block the machine in a raised position. Using a suitable lever, check the clearance of the tumbler bushing by lifting and then lowering the tumbler. Replace the bushing if the clearance is excessive.
The take-up tumblers do not require replacement or repair very often. The most common problem encountered is bushing wear. However, it is possible for the tumbler to develop cracks. When cracks do occur, they can be repaired by
gouging out metal on both sides of the crack, and welding the crack. Follow welding instructions in APPENDIX.
If bushing replacement is needed, the tumbler must be removed from the machine. To accomplish this:
1. Position the machine so that the take-up tumbler to be removed is over a slight depression (about 6" deep). This depth will be enough to relieve the weight of the machine from the tumbler.
2. Relieve crawler belt tension and separate the crawler belt as described in the topic CRAWLER BELT REPLACEMENT. Separation of the belt should take place at a point near the take-up tumbler, and the links laid back out of the way.
3. Remove the shim guards and lube lines if so equipped.
4. Using a suitable lifting device to support the take-up tumbler, remove the shaft from the tumbler. Lift the tumbler from the crawler frame.
5. Remove the supports and shims from the crawler frame.
6. Inspect the tumbler bushings. Remove and replace the bushings if necessary.
7. Inspect the tumbler shaft and replace if necessary.
1. TAKE-UP TUMBLER
2. TUMBLER BUSHING
3. SHAFT SUPPORT
4. TUMBLER SHAFT
5. SHAFT RETAINING PIN
6. SOLID SHIM
7. SLOTTED SHIMS
8. CRAWLER FRAME
8. Inspect and clean the shaft supports. Replace if worn.
9. Inspect the crawler frame in the areas where the supports slide. Rebuild and grind if worn.
10. Lubricate the tumbler bore and shaft. Install the supports in the crawler frame. Using a suitable lifting device, position the tumbler in the crawler frame.
11. Install the bearing tumbler shaft and secure with the shaft retainer pin.
12. Reassemble the crawler belt.
13. Adjust the crawler belt tension as per topic CRAWLER BELT ADJUSTMENT.
14. Replace the shim guards and lube lines if so equipped.
15. Propel the machine to distribute the lubricant evenly in the tumbler bushing and check operation of tumbler.
Inspect the drive tumbler for cracked and broken lugs and other defects that can impair normal tumbler function and belt tracking (figure 1-2-8). Check the tumbler retainer bolts for tightness.
Repair of the drive tumbler is limited to repair welding of the lugs or roller area or replacement of the entire unit. Refer to the welding instructions in the APPENDIX for exact weld repair procedures.
To replace the drive tumbler:
1. Relieve the crawler belt tension and separate the crawler belt as detailed in the CRAWLER BELT REPLACEMENT topic of this manual. Separation of the crawler belt should take place near the drive tumbler and the links laid back out of the way.
2. Using the machine leveling jacks, raise the machine sufficiently to allow the drive tumbler to clear the lugs on the crawler belt. Block the machine in the raised position.
3. Remove the tumbler retainer bolts and remove the tumbler from the planetary gearbox.
NOTE: The tumbler retainer bolts are metric bolts.
4. Inspect the drive tumbler. Repair or replace if the lugs or rolling surface are worn or damaged.
5. Install the drive tumbler on the planetary gearbox. Torque the bolts item 2, (fig. 1-28), to 2,600 ft.lbs. (lubed) and item 4 to 1,100 ft.lbs. (lubed).
6. Remove blocking and lower machine. Verify that all of the rollers and the drive tumbler are resting on the roller path of the belt.
7. Assemble and adjust the tension of the crawler belts as described in CRAWLER BELT ADJUSTMENT.
8. Propel the machine to check the operation of the drive tumbler.
NOTE: tighten bolts (items 2 & 4) as follows:
Item 2- 2,600 ft.lbs. (lube d)
Item 4- 1,100 ft.lbs. (lube d) DRIVE
1. DRIVE TUMBLER 2. TUMBLER BOLT (METRIC) 3. PLANETARY GEARBOX 4, GEARBOX BOLT (METRIC) 5. CRAWLER FRAME• Thank you very much for reading the preview of the manual.
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