CAT BUCYRUS 49HR BLAST HOLE DRILL MAINTENANCE and OPERATION MANUAL SN 141239

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49HR Blast Hole Drill

Maintenance and Operation Manual

Manual No. 10483

sn: 141239, Lot 85

–Table of Contents–

This manual is divided into major sections covering the various serviceable components and systems of the 49HR Blast Hole Drill. These sections and their contents are organized as shown below.

Section 1 -INTRODUCTION

Section 2 -OPERATION

Section 3 -LUBRICATION

Section 4 -PREVENTIVE MAINTENANCE

Section 5 -SERVICE PROCEDURES

Section 6 -BRAKES AND COUPLINGS

Section 7 -COMPRESSED AIR SYSTEM

Section 8 -HEATING, VENTILATION AND AIR CONDITIONING

Section 9 -ENGINEERING DATA

IMPORTANT NOTE

This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability. © 2007 Bucyrus International, Inc. All Rights Reserved.

2007

DANGER:

THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

DANGER:

DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY.

The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.

DANGER:

DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.

Section 1 Introduction

GENERAL INFORMATION

This manual is designed to assist the owner in the operation and maintenance of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner. When a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.

THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with the associated item/part numbers for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments. Records on each machine are filed by serial number and when given this number, your machine’s specific design and original equipment is accessed quickly by the Bucyrus International parts representative.

Periodic additions or revisions may be made to this manual. These can be ordered and will be mailed directly from the factory. Should you require additional information or factory service assistance contact your regional service representative or:

Bucyrus International, Inc.

1100 Milwaukee Avenue

P.O. Box 500

South Milwaukee, Wisconsin, USA53172-0500

Telephone (414)-768-4000

It is Bucyrus International’s policy to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations to install such changes on machines sold previously.

Due to this ongoing program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve our machines.

The safety alert symbols displayed here and throughout this manual, are used to call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine.

Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions. If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional Bucyrus service representative or the factory.

The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.

NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.

CAUTION:This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.

DANGER:This signal word denotes an imminently dangerous hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

DANGER:This signal word denotes an imminently dangerous electrical hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

SAFETY PRECAUTIONS

General Precautions:

•The employment of qualified maintenance personnel, through a scheduled maintenance program, is the best way to minimize machine downtime and maximize productivity of equipment.

•Keep hands, feet, and clothing away from rotating parts.

•Wear a hard hat, safety shoes and protective lenses at all times.

•Replace any and all safety and warning placards if they are defaced or removed from the machine.

•Think before you act. Carelessness is one luxury the service man cannot afford.

•Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup.

•Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip off of the hook if they are not functioning properly.

•If a heavy item begins to fall, let it fall, don’t try to catch it.

•Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.

•Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure all spillage is cleaned up.

•Electrical cords and wet metal floors make a dangerous combination.

•Regularly inspect for any loose bolts or locking devices and properly secure them.

•Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless you are qualified.

•Check limit switches for proper operation.

•After servicing, be sure all tools, parts or servicing equipment are removed from the machine and secured in an appropriate storage area.

•Mechanical Brakes are designed for use as static holding brakes only. Use as a motion (dynamic) brake in emergency situations only.

•Use proper interior and exterior lighting.

•Install and maintain proper grounding and ground fault protection systems.

•Perform functional tests of all safety circuits.

•Allow electrical inspection and maintenance to be performed only by a qualified electrician.

•Use extreme caution when working around drilled holes.

Bucyrus International, Inc.

Maintenance Precautions:

•Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They could get caught on moving parts causing serious injury.

•Always wear a safety belt or harness when the danger of falling exists.

•Always have a second person to monitor the lifeline when working in confined spaces.

•Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation.

•Never utilize the machine air or hydraulic systems for support when working on the machine. Deactivate or isolate the entire system prior to performing maintenance.

•Equipment should be parked on level ground at all times during machine servicing and periods of idleness.

•Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases, pipe arms, etc.) Always work within the limitations of the equipment being utilized.

•Be sure heavy items are properly rigged and supported from cranes or hoists before removing supporting members from the machine.

•Utilize guide lines or ropes to minimize the swing of suspended heavy components.

•Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times.

•Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they could fail.

•When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.

•When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart.

•Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Always be sure to wear safety glasses.

•Use extreme caution when using compressed air to dry parts. Use approved air blowguns, do not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.

•Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

•Protective eye goggles should be worn at all times when working on the air conditioning system. Work on the air conditioning system only in a well ventilated area.

•Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.

•Always wear approved rubber gloves, and use insulated hooks or tongs when handling trail cable.

Operating Precautions:

•Wear hearing protection when exposed to the following noise levels in excess of the period indicated:

8 hours at 90 dBa

4 hours at 95 dBa

2 hours at 100 dBa

1 hour at 105 dBa

30 minutes at 110 dBa

15 minutes at 115 dBa

•When in doubt about the noise level, wear approved hearing protection.

•Do not attempt to get on or off the machine while it is in operation. Notify the operator prior to any attempt to board/exit the machine.

•Do not move or operate the machine without first knowing the location and purpose of all personnel, test or support equipment, on or near the machine.

•Do not allow unauthorized personnel on board the machine while in operation.

•Use audible signals to warn of machine movements. A signal horn button is provided for this purpose.

•Do not propel until the travel route has been cleared of obstructions.

•Do not propel the machine on a slope greater than specified in the stability limits shown on the STABILITY CHART in this manual.

•Do not leave the rotary gearbox suspended in the air when leaving the machine unattended.

•Prevent trail cable from being dragged on the ground for long distances or at high speeds.

•Limit the amount of cable being dragged by the machine. Pulling too much cable will damage both the cable and the machine.

FIRE PREVENTION CONSIDERATIONS

Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.

DO NOT smoke while handling flammables or when near batteries.

Inspect all lines, tubes, and hoses carefully. Tighten all connections to their recommended torque specification. See Section 4 of this manual for the Scheduled Maintenance recommendations and the Walk Around Inspection procedure.

Repair or replace loose or damaged lines, tubes, and hoses as soon as possible.

Make certain that all clamps, guards, and shields are replaced correctly so as to prevent vibration and the chafing of parts during operation.

DO NOT carry flammable fluids such as gasoline or solvents on board the machine.

DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged lines, tubes, or hoses. Replace them immediately.

DO NOT start the machine or move any of the controls if a warning tag is attached to the controls or the start panel.

Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.

Keep all structural frame compartments, walkways, and work areas clean and free of lubricant residue.

NEVER weld, burn, or perform service on the machine alone.

STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS

These signals are derived from ANSI-B30.5-1868 and are intended to provide standardization to the signaling used in communication between maintenance personnel and crane operators during the maintenance cycle.

HOIST Extend forearm upward, keeping forefinger extended and pointing up, make small circular movements with hand.

LOWER Extended arm downward, keeping forefinger extended and pointed down, make small circular movements with hand.

MAIN HOIST Tap fist on head until signal received by operator, then use standard signals.

USE WHIP LINE (Auxiliary Hoist) Tap elbow with open hand until signal received by operator, then use standard signals.

RAISE BOOM Extend arm fully with fingers closed and thumb pointing upward.

STOP Extend arm fully with fingers extended and palm facing down.

EMERGENCY STOP With arm fully extended, fingers fully extended and palm facing down, move arm rapidly along a horizontal plane.

TRAVEL With arm extended forward, hand open and raised at wrist, make a pushing motion in the desired direction of movement.

DOG EVERYTHING Clasp hands together in front of body.

TRAVEL (both tracks) With both fists clenched in front of body, make a circular motion with the desired direction of motion (forward or reverse) duplicated with fists.

LOWER BOOM Extend arm fully with fingers closed and thumb pointing down.

MOVE SLOWLY While giving any motion signal, hold other hand motionless in front of desired signal hand. (Hoist slowly is example provided.)

RAISE BOOM AND LOWER LOAD Extend arm horizontally with fingers extended and thumb pointing upward, alternately open and close fingers for the duration of the desired movement.

LOWER BOOM AND RAISE LOAD Extend arm horizontally with fingers extended and thumb pointing downward, alternately open and close fingers for the duration of the desired movement.

SWING Extend arm horizontally with index finger extended in desired direction of swing.

TRAVEL (Single Track) Use a raised fist on the side that remains locked and make a vertical circular motion in front of chest for the direction and side of desired movement.

EXTEND BOOM (Telescoping Booms) Place both hands in front of body with palms upward, fingers clenched, and thumbs extending outward.

RETRACT BOOM (Telescoping Booms) Place both hands in front of body with palms upward, fingers clenched, and thumbs extending inward.

EXTEND BOOM (Telescoping Booms) With fingers clenched and thumb extended toward body, use a single hand motion to tap on chest with thumb of hand.

RETRACT BOOM (Telescoping Booms) With fingers clenched and thumb extended away from body, use a single hand motion to tap on chest with heel of hand.

WARNING SIGNS AND DECALS

The placards depicted below are mounted on the machine as delivered from Bucyrus International, Inc. These hazard warning placards convey information to operators, maintenance personnel, or anyone who will be on or near the machine. The information is designed to help prevent situations which may result in injury to personnel or damage to the machine.

Stored Energy Signs

MACHINE OVERVIEW

This machine is designed and constructed to provide efficient service under the most severe conditions. It is built to the highest possible standards and will provide trouble free operation if properly maintained.

PROPEL MACHINERY

The propel system of this machine is a chainless hydraulic drive system which will allow the separate tracks to counter-rotate. This capability provides the machine with the capacity to turn completely around within it’s own length. Each track is driven by a hydraulic motor and a planetary gearbox equipped with a hydraulically released, spring activated brake. The machine is capable of 2 different propel speed ranges. The lower speed range is used for maneuvering in close spaces while the high speed range is used for tramming in open areas, over long distances.

MAIN FRAME AND DECKS

The main frame is of welded box type construction with integrally placed mast supports and jack towers.

MAIN AIR SYSTEMS

The screw compressor is located within the machinery house just forward of the hydraulic pump gearbox. The rotary screw compressor is an oil flooded, single stage twin screw type compressor which has a nominal rating of 3,000 cfm (84.9m3/min), @ 65 psi (74.7 m3/min) and a maximum operating pressure of 65 psi.

Air Compressor

HYDRAULIC SYSTEM

Hydraulic pressure for operation of this machine is provided by four separate pumps. These pumps are driven by the electric motor located in main machinery house, forward of the hydraulic filters and reservoir.

The machine has 2 separate, though not completely independent hydraulic systems, the OPEN and CLOSED circuits. Both draw fluid from a common reservoir.

OPERATOR’S CAB

The sound insulated operator’s cab of the 49HR provides a sealed, comfortable enclosure from which the operator can perform the tasks involved with the operation of the machine. The location and design of this compartment have been structured to provide the optimum viewing angles with immediate accessibility. The swivel mounted chair provides easy access to all required controls. The auxiliary control console is within reach to provide access to additional functions of the machine. The cab is provided with dual doorways to the main deck.

MAST

The mast is a fabricated structure of steel tubes and formed plates. The major structure is composed of vertical tubes welded together with back bracing. The mast functions to provide the mounting and guide for the equipment required to operate the drilling function of the machine. The mast is capable of being positioned at any 5o increment within it’s operating range from 65 degrees through 90 degrees (vertical). The mast can be raised and lowered by 2 (two) 8.00 inch (203mm) hydraulic cylinders.

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