BUCYRUS 49RII Diesel Electric Blast Hole Drill Technical Manual – CAT Rotary Track Drills 49RII – PDF DOWNLOAD
DESCRIPTION:
BUCYRUS 49RII Diesel Electric Blast Hole Drill Technical Manual – CAT Rotary Track Drills 49RII – PDF DOWNLOAD
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 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.
TABLE OF CONTENTS:
BUCYRUS 49RII Diesel Electric Blast Hole Drill Technical Manual – CAT Rotary Track Drills 49RII – PDF DOWNLOAD
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 1-2-2
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 1-2-11
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 1-3-5
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
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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 2 HYDRAULIC SYSTEM
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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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-ll
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
CHAPTER 3 AIR SYSTEM
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
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CHAPTER 4 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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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 SA-1
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- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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