FOREWORD
The purpose of this manual is to provide information concerning the general maintenance of the 49-RII Diesel/Electric 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, the diesel/electric drive, 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-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 compo- nent 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 prod- ucts. 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
General Offices: South Milwaukee, Wisconsin, U.S.A. LIT S388 392
BI005470
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PAGE CHAPTER 1 MECHANICAL
SECTION 1 - MAINTENANCE PROCEDURE General ................................................................................................................................... 1-l-1 Maintenance Schedules and Reports .................................................................... 1-1-1 Safety ...................................................................................................................................... 1-l-2 General ......................................................................................................................... 1-1-2 In-operation Maintenance ........................................................................................ 1-l-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 ...................................................................................................... 1-2-2 Belt Replacement ....................................................................................................... 1-2-3 Lower Rollers ........................................................................................................................ 1-2-4 Upper Rollers ........................................................................................................................ 1-2-5 Take-up Tumblers ................................................................................................................ 1-2-5 Drive Tumbler ...................................................................................................................... 1-2-7 Planetary Gearbox ............................................................................................................... 1-2-7 Crawler Frames .................................................................................................................. 1-2-10 Axles ..................................................................................................................................... 1-2-ll SECTION 3 - MAINFRAME Mainframe ............................................................................................................................. 1-3-1 Bit Viewing Hatch ............................................................................................................... 1-3-l Mast A-Frame ....................................................................................................................... 1-3-2 Leveling Jacks ...................................................................................................................... 1-3-2 Machinery House ................................................................................................................. 1-3-5 House Pressurization Fan and Filter ............................................................................. 1-3-6 Walkways and Ladders ...................................................................................................... 1-3-6 Operator's Cab ...................................................................................................................... 1-3-6 Operator's Controls .................................................................................................... 1-3-7 Ventilation Unit ......................................................................................................... 1-3-7 Hydraulic Pump Drive ........................................................................................................ 1-3-7 Diesel Engine/Alternator Set ......................................................................................... 1-3-10 Diesel Engine Radiator ................................................................................................... 1-3-11 General Safety and Maintenance ........................................................................ 1-3-11 Removal of Tubes .................................................................................................... 1-3-14 Installation of Tubes .............................................................................................. 1-3-14 Core with Center Tanks ........................................................................................ 1-3-15 External Cleaning ................................................................................................... 1-3-15 Diesel Engine Air Filter .................................................................................................. 1-3-15 Diesel Engine Saver .......................................................................................................... 1-3-15 Hose Routing and Installation Precautions ...................................................... 1-3-15 SECTION 4 - MAST Mast Structure ..................................................................................................................... 1-4-1 Mast Safety Slings .............................................................................................................. 1-4-2 Rotary Gearcase ................................................................................................................... 1-4-2 Drive Shaft Adjustment ............................................................................................ 1-4-2 Repair ........................................................................................................................... 1-4-3
TABLE OF CONTENTS
MAINTENANCE
BI005470 Rotary Motor ......................................................................................................................... 1-4-8 Rotary Coupling ................................................................................................................... 1-4-8 Rotary/Pulldown Guide Frame ....................................................................................... 1-4-10 Guide Roller Adjustment ....................................................................................... 1-4-10 Repair ......................................................................................................................... 1-4-10 Pulldown Gearcase ............................................................................................................ 1-4-15 Hoist Brake ......................................................................................................................... 1-4-19 Inspection ................................................................................................................... 1-4-19 Brake Wear Adjustment ........................................................................................ 1-4-19 Replacement of Friction Discs .............................................................................. 1-4-20 Disassembly of Magnet Body and Armature .................................................... 1-4-20 Reassembly of Magnet Body and Armature ...................................................... 1-4-21 Pipe Racks ........................................................................................................................... 1-4-21 Tool Wrenches .................................................................................................................... 1-4-24 Auxiliary Winch ................................................................................................................. 1-4-25 Mast Braces ........................................................................................................................ 1-4-25 Repair ......................................................................................................................... 1-4-25 Adjustment ................................................................................................................. 1-4-25 CHAPTER
HYDRAULIC
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-l Weekly Maintenance Checks ............................................................................................. 2-2-2 Oil Reservoir Repairs .......................................................................................................... 2-2-2 Hydraulic Oil Cooler ........................................................................................................... 2-2-2 General Safety & Maintenance .............................................................................. 2-2-2 Removal of Tubes ....................................................................................................... 2-2-2 Installation of Tubes ................................................................................................. 2-2-4 External Cleaning ...................................................................................................... 2-2-4 Leveling Jack Counterbalance Valve Pressure Relieving Procedure ...................... 2-2-4 Rear Jacks ................................................................................................................... 2-2-4 Front Jack ................................................................................................................... 2-2-5 Prestart Inspection .............................................................................................................. 2-2-5 Hydraulic Systems Tests .................................................................................................... 2-2-5 Propel Pump Charge Pressure Check .................................................................. 2-2-6 Control Pressure Check ............................................................................................ 2-2-6 Propel Enable Valve and Low Speed Select Check ........................................... 2-2-6 Jack Cylinder Check in Manual Mode ................................................................. 2-2-7 Flow Control Check ................................................................................................... 2-2-7 Jack Cylinder Drift Test .......................................................................................... 2-2-8 Brake Release Pressure Check .............................................................................. 2-2-8 Propel Brake Emergency Release Check ............................................................. 2-2-8 Propel Pump Main Relief Pressure Check .......................................................... 2-2-8 Crawler Function Check ........................................................................................... 2-2-9 Bit Viewing Hatch Check ......................................................................................... 2-2-9 Boarding Stair Check ................................................................................................ 2-2-9 Main Flow Valve Check ............................................................................................ 2-2-9 Breakout Wrench and Tool Wrench Check ......................................................... 2-2-9
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SYSTEM
CHAPTER 3 AIR SYSTEM
BI005470 Dust Curtain Cylinders ............................................................................................ 2-2-9 Dust Seal Slider ......................................................................................................... 2-2-9 Mast Lock (Station 6 of 7-station manifold) ...................................................... 2-2-9 Mast Brace Lock Cylinders (Station 4 of 7-station manifold) ...................... 2-2-10 A-Frame Lock Cylinders (Station 5 of 7-Station Manifold) .......................... 2-2-10 Mast Lock Constant Pressure Check .................................................................. 2-2-10 Mast Brace Constant Pressure Check ................................................................ 2-2-10 A-Frame Lock Constant Pressure Check ........................................................... 2-2-10 Mast Raise/Lower .................................................................................................... 2-2-10 Auxiliary Winch ........................................................................................................ 2-2-11 Pipe Rack Position .................................................................................................. 2-2-11 Troubleshooting Leveling Jack Flow OCntrol Valve for Failure ................. 2-2-11 Pipe Rack Lock and Gate Cylinder Port Relief Setting 2-2-11 Check Jacks in Auto Level Mode ........................................................................ 2-2-12 Hydraulic Lube Drive Pressure Reducing Valve Setting 2-2-12 Test Point Locations ............................................................................................... 2-2-13
SECTION 1 - SYSTEM OPERATION MAIN AIR SYSTEM ............................................................................................................ 3-l-1 SECTION 2 - GENERAL MAINTENANCE Main Air System .................................................................................................................. 3-2-1 General ......................................................................................................................... 3-2-1 Intake Air Filter .................................................................................................................. 3-2-1 Filter Service ............................................................................................................... 3-2-2 Compressor Oil Cooler ........................................................................................................ 3-2-2 Description ............................................................................................................................ 3-3-1 Coupling Alignment ............................................................................................................. 3-3-1 SECTION 3 - ROTARY SCREW COMPRESSOR (A-C COMPRESSOR CORP. KS-31-LU OR KS-27-LU) Parallel Misalignment ............................................................................................... 3-3-2 Angular Misalignment ............................................................................................... 3-3-2 Start-Up Procedure .............................................................................................................. 3-3-2 Shutdown ............................................................................................................................... 3-3-3 Controls and Instruments .................................................................................................. 3-3-3 Air Pressure Control System .................................................................................. 3-3-3 Reduced Unloaded Horsepower Feature .............................................................. 3-3-8 Variable Volume Feature (Optional) .................................................................. 3-3-10 Lubrication System ............................................................................................................ 3-3-11 Compression Oil System ........................................................................................ 3-3-11 Oil Specifications ..................................................................................................... 3-3-12 Filling Oil System (Initially) ................................................................................ 3-3-12 Oil Level Gauge ........................................................................................................ 3-3-12 Adding Oil Between Changes ............................................................................... 3-3-12 Oil Change Intervals .............................................................................................. 3-3-12 Draining Oil System ............................................................................................... 3-3-12 Refilling Oil System ............................................................................................... 3-3-13 Compressor Oil Strainer and Filters .................................................................. 3-3-13 Compressor Oil Cooler ........................................................................................... 3-3-14 Thermostatic Control Valve .................................................................................. 3-3-14 Compressor Oil Separator ..................................................................................... 3-3-15 Air Filters .................................................................................................................. 3-3-15 Maintenance Schedule ............................................................................................ 3-3-16
BI005470 CHAPTER
DUST CONTROL SECTION 1 - GENERAL MAINTENANCE Drilling Platforms and Dust Curtains ............................................................................... 4-1 Water Injection ........................................................................................................................ 4-1 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 After Venting, The Indicator Stems On The Injectors Do Not Return To Their Normal Position .......................................................................................................... 5-2-1 Lube Pump ................................................................................................................... 5-2-2 Lubrication ................................................................................................................... 5-2-2 CHAPTER 6 TROUBLESHOOTING .................................................................. 6-1-1 APPENDICES APPENDIX Al - GEAR INSPECTION General .................................................................................................................................... lA-1 APPENDIX A2 - BOLT TORQUING Torque Wrench Method ...................................................................................................... 2A-1 Turn of the Nut Method .................................................................................................... 2A-2 APPENDIX A3 - PINION, BRAKE DRUM AND COUPLING INSTALLATION Removal from Shaft ............................................................................................................ 3A-1 Mounting on Shaft ............................................................................................................... 3A-1 APPENDIX A4 - LUBE BENCHMARKS MPG - Multi-Purpose Type Grease .................................................................................. 4A-1 ACSL - Air Compressor (Screw Type) Lubricant ......................................................... 4A-2 DPTL - Drill Pipe Thread Lubricant .............................................................................. 4A-3 MPO - Multi-Purpose Oil ................................................................................................... 4A-4 OGL - Open Gear Lubricant ............................................................................................. 4A-5 RGL - Regular Type Gear Lubricant .............................................................................. 4A-7 RWRL - Running Wire Rope Lubricant ........................................................................ 4A-10 HYDO - Hydraulic Oil ...................................................................................................... 4A-11 APPENDIX A5 - RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRINCIPAL STRUCTURES ON BLAST HOLE DRILLS General .................................................................................................................................... 5A-1 Maintenance Welding .......................................................................................................... 5A-1 Structural Materials ........................................................................................................... 5A-1 Welding Electrodes .............................................................................................................. 5A-2
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BI005470 Preheat Requirements ........................................................................................................ 5A-2 Removal of Cracks ............................................................................................................... 5A-3 Weld Groove Preparation ................................................................................................... 5A-3 Drill Pipe Welding ............................................................................................................... 5A-4 Welding Technique .............................................................................................................. 5A-5 Weld Inspection .................................................................................................................... 5A-5 Repair of Broken Parts ...................................................................................................... 5A-5 APPENDIX A6 - PREVENTIVE MAINTENANCE CHECK LIST Level 1 Inspection ............................................................................................................... 6A-1 Level 2 Inspection ............................................................................................................... 6A-5 Level 3 Inspection ............................................................................................................... 6A-7 APPENDIX A7 - SPECIAL FITS ...................................................................................................... 7A-1 APPENDIX AS - AEROQUIP ORS CONNECTIONS ...................................................................... 8A-1
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