Cat BUCYRUS 59R ELECTRIC BLAST HOLE DRILL MECHANICAL MAINTENANCE MANUAL – PDF DOWNLOAD

Technical Manual

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FOREWORD

The purpose of this manual is to provide information concerning the general maintenance of the 59-R Rotary Blast Hole Drill.

The Model 59-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 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-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 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 pubUcation. 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

BUCYRUS-ERIE COMPANY

BUCYRUS-ERIE COMPANY

General Offices: South Milwaukee. Wisconsin. U.S.A. 393

General Offices: South Milwaukee. Wisconsin. U.S.A. 393

CHAPTER 1

TABLE OF CONTENTS

OF CONTENTS

MAINTENANCE

CHAPTER 1 MECHANICAL MAINTENANCE

CHAPTER 2 HYDRAULIC SYSTEM

CHAPTER 4 DUST CONTROL

CHAPTER 5 LUBRICATION

APPENDICES

APPENDIX

CHAPTER 1 MECHANICAL MAINTENANCE

MECHANICAL

SECTION 1- MAINTENANCE

PROCEDURE

GENERAL

GENERAL

This section of the manual describes those aspects of preventive maintenance such as scheduled reports and safety precautions as they pertain to the 59-R drill.

This of manual describes those aspects preventive such uled safety as to drill.

MAINTENANCE SCHEDULES AND REPORTS

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. 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?

Ideally, be approached from standpoint and a regularly approach to and maintenance To establish a and an the most ful available. Scheduled inspections Mechanical and Maintenance are most Either that part the mine's file on the machine. should explicit, every machine. complete record machine's time time all observations tions records, items that cause machine can or the machine availability coordinated with the should be and scheduling any maintenance or following should considthe the machine result of a of the problem a

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?

repairs a later date, affected? Can Will than worthwhile?

9. How long will the machine be down?

9. How long 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?

maintenance repair has scheduled, following points into all needed acavailable are they Are all replacement on hand available? of accomplish been all reassembly available? repair 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?

6. Will there adequate for been How long will the

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?

Once repair accomplished, be with things in problem permanently guarantee is not again?

3. Is with the for

3. Is consultation with the manufacturer for design improvement necessary?

4. costs incurred in downtime, tools labor?

4. What costs were incurred in downtime, parts, tools and labor?

Could the .

5. Could the problem have been prevented by prior action?

A CAUTION: Many of the components of the 59-R 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 lifting height and radius, and capacity of the lifting device before lift.. ing. Failure to follow all applicable safety rules when lifting can cause serious or fatal injury to personneL

A CAUTION: Many of the components of the 59-R 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 lifting height and radius, and capacity of the lifting device before lift.. ing. Failure to follow all applicable safety rules when lifting can cause serious or fatal injury to personneL

A CAUTION: When removing certain ... machine 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 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.

A CAUTION: When removing certain machine 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 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 of removal might involve using a soft metal hammer or a hydraulic jack with applicable fixtures.

GENERAL

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 safe practices.

safety in maintenance of always excavating be operations inMany are and which limits life; thus new, all such built-in strength and loss of durability from gradual If, neglected, these where they problem. to various to the safety problem. and procedures to avoid unsafe Review the manual to refresh these Supervisor, maintenance folsafe practices.

MAINTENANCE machines be inspected regular proper adjustment operating mechanisms, wear of other should be determined a safety problem vital It should performed by

TN-OPERATION MAINTENANCE

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 as upkeep as while there such and replacement, shut duties can be safely and efhandled at shift change when the mais lubrication function the operation cycles premeasured life the units. manually in safe extended fittings hands distance. this

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 , C!ngthen the wear life of the machinery units. ther parts of the machinery may be manually .J.bricated in a safe manner through extended grease or oil fittings designed to keep the operator's hands at a safe distance. Where this 1-1-2

is not possible, the machine must be shut down during the required lubrication.

the the required lubrication.

A repair not complete until guards, and devices replaced

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 AND DURING

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:

The operator sure a or The should by falling rock a yielding support surface. adjustment, erator

• Secure the rotary drive unit and tool string.

• Set all brakes.

• the drive all brakes.

• De-energize control functions and tag.

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

• De-energize control and else accidental movement

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.

If is essential to the repair, it should when clear electrical mechanical The should only be energized and repair work personnel notify operator of If is should the "OFF" position and tag should be by who use connections.

Approved equipment insulated or tongs voltage handled. Only electricians permitto directly maintain electrical as transformers, and switches.

often due handling As measure, handling equipment whenever The mining foreman safer and work providing ing should a funknowledge of and rather their

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.

LOWER WORKS FIGURE

surface of the crawler links (figure 1-2-2). The minimum clearance is 12" and the maximum clearance is 14" at which time the crawler belts must be adjusted. Do not operate with belt slack in excess of 18".

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 tum 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 (25 ton), supplied with the machine, behind each of the supports.

4. Remove several shims from behind the supports.

CRAWLER BELT SAG

HYDRAULIC JACK

CRAWLER

CRAWLER REPLACEMENT

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.

5. Actuate the hydraulic jacks push the to belt tension. Make sure the supports slide in the do not become cocked.

6. Insert shims in the supports to maintain the Several provided. Be that the the same each

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

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.

8. Reinstall the shim guards on the crawler Repeat for the other crawler belt if necessary. blocking and machine.

LINK REPLACEMENT (figure

To replace a link in the crawler belts:

LINK REPLACEMENT (figure in

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.

1. Propel the machine position tive link in accessible position Remove tension belt removing of the tensioning shims from the take-up supports. to the CRAWLER BELT ADJUSTMENT for details procedure.

Secure the belt against unwanted

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.

4. device Part the belt defective link two one end lower the the crawler belt with the defective to the ground.

CRAWLER BELT REPLACEMENT

FIGURE 1-2-3

1. TUMBLER SHAFT SUPPORT

2. SHIMS

3. HYDRAULIC JACK

4. HYDRAULIC HOSE AND FITTINGS

5. HYDRAULIC PUMP

6. CRAWLER BELT

HOSE AND HYDRAULIC PUMP

BELT

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