CAT Bucyrus 45-R 47-R Blast Hole Drill Mechanical Maintenance Manual BI005447 – PDF DOWNLOAD

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CAT Bucyrus 45-R 47-R Blast Hole Drill Mechanical Maintenance Manual BI005447 – PDF DOWNLOAD

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CAT Bucyrus 45-R 47-R Blast Hole Drill Mechanical Maintenance Manual BI005447 – PDF DOWNLOAD

Language : English
Pages : 237
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus 45-R 47-R Blast Hole Drill Mechanical Maintenance Manual BI005447 – PDF DOWNLOAD

FOREWORD:

This purpose of this manual is to provide information concerning the general maintenance of
theBucyrus­ Erie® 45/47-R Rotary Blasthole Drill.
The 45/47-R drill consists of three major units; the lower works, the mainframe, and the mast.

• The lower works provides a foundation for the main frame and contains most of the equipment
  necessary to propel the drill.
• The main frame includes the hydraulic, main air and auxiliary air systems, the
  hoist-propel transmission and the machinery house. The machinery house encloses the majority of the
  mechanical equipment necessary for the main and auxiliary air system, the hydraulic systems and
  electrical control systems. The machinery house is pressurized with filtered air to minimize dirt
  and heatbuild­ up. The operator’s cab is located at the rear of the main frame and contains the
  operator’s station.
• The mast is mounted to the rear of the main frame and contains the machinery required for rotation
  and handling of the tool string.
• This manual is consists of six chapters, each divided into sections. A table of contents is located
  in the front of this manual.
• Familiarize yourself with the contents of this manual so that you can easily locate particular
  information when you need it.

TABLE OF CONTENTS:

CAT Bucyrus 45-R 47-R Blast Hole Drill Mechanical Maintenance Manual BI005447 – PDF DOWNLOAD

CHAPTER 1 – MECHANICAL MAINTENANCE
PAGE
Section 1 – MAINTENANCE PROCEDURE
General 1
Maintenance Schedules and Reports 1
Safety 2
General 2
In-Operation Maintenance 2
Precautions Before and During Maintenance Work 2
Section 2 – LOWER WORKS
Crawler Belts 5
Adjustment 5
Link Replacement 6
Belt Replacement 7
Lower Rollers 7
Upper Rollers 8
Drive Tumblers 9
Take-Up Tumbler 10
Crawler Frames 12
Axles 13
Propel Final-Drive Chains 15
Section 3 – MAINFRAME
Maintenance and Mast Support 17
Leveling Jacks 17
Machinery House 19
House Ventilation Fan and Filter 19
Walkways and Ladders 19
Operator’s Cab 20
Operator’s Seat 20
Operator’s Controls 20
Ventilation Unit 20
Hoist-Propel Gearcase 20
Repair 21
Removal and Installation of Gearcase 21
Gearcase Suspension 22
Hoist-Propel Gearcase Disassembly and Assembly 23
Hoist Shaft 24
Second Intermediate Shaft 26
Idler Shaft 26
Propel Shaft 27
Propel Clutches 28
Hydraulic Hoist/Propel Motor Gearcase 29
Propel Machinery 31
Repair 31
First Intermediate Shaft 31
Second Intermediate Shaft 33
Propel Chain Adjustment 34
Hoist Brake 35
Auxiliary Reel Brake 37
Propel Brakes 39
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Hoist-Auxiliary Reel Clutch Lever 41
Depth Indicator 43
Propel Towing Emergency Brake 44
Diesel Engine 44
Diesel Engine Radiator Fan Drive (Hydraulic) 44
Replacement of Drive Belts 46
Belt Adjustment 47
Cable Reel 47
Repair 47
Cable Reel Controls 51
Adjustment 51
Section 4 – MAST
Mast Structure 53
Mast Lock Latch 54
Rotary Gearcase 55
Drive Shaft Adjustment (47-R) 55
Repair (47-R) 55
Rotary Motor (47-R) 59
Adjustments (45-R) 60
Repair (45-R) 62
Rotary Motor (45-R) 64
Rotary Coupling 65
Rotary Shock Sub 65
Rotary Guide Frame 67
Pulldown Chains 70
Pulldown Chain Equalizer (Hydraulically Operated) 72
Pulldown Chain Equalizer (Mechanical Operation) 74A
Tool Racks 75
Tool Wrenches 77
Back Braces 78
CHAPTER 2 – HYDRAULIC SYSTEM
Section 1 – SYSTEM OPERATION
Hydraulic System Operation 81
Hydraulic Cylinder Circuit 81
Hydraulic Hoist/Propel Circuit 83
Chain Equalizer Circuit 86
Section 2- GENERAL MAINTENANCE
Hydraulic System Cleanliness 87
Oil Requirements 87
Oil and Filter Changes 87
Weekly Maintenance Checks 88
Oil Reservoir Repairs 88
Hydraulic Hoist/Propel Tests 88
Section 3 – COMPONENT MAINTENANCE
Hydraulic Pump Overhaul 95
Disassembly 95
Cleaning 96
Inspection 96
Reassembly 96
Test Procedure 97
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Main Valve Banks 97
General 97
Disassembly 97
Cleaning, Inspection and Repair 97
Assembly 98
Hydraulic Oil Cooler 99
Weekly Maintenance Check 99
1000 Hour Maintenance Check 99
Yearly Maintenance Check 99
CHAPTER 3 – AIR SYSTEMS
Section 1 – SYSTEMS OPERATION
General 101
Main Air System 101
Auxiliary Air System 101
Safety 101
Section 2 – GENERAL MAINTENANCE
Main Air System 105
Intake Air Filter – Box Type 105
Intake Air Filter – Tubular Type 105
Filter Replacement 106
Drive Belts 106
Belt Adjustment 106
Compressor Lubricator (Vane Compressor Only) 107
Feed Rate 107
Viscosity Grade 108
Lubricator Daily Maintenance Check 108
Lubricator Weekly Maintenance Check 108
Lubricator Service 108
Lubricator Priming 108
Compressor Radiator 108
Safety Valve Settings 109
Drill Pressure 109
Auxiliary Air System 109
Auxiliary Air Compressor 109
Miscellaneous Components 110
Unloader Check Valve Service 110
Tanner De-leer (Optional) 110
Air Tank 110
Air Tank Valves 110
Pressure Switch 111
Filter 111
Anti-Freezer 111
Maintenance Procedure for Air Dryer 112
Desiccant Canister Removal 112
Purge Valve Removal 113
Section 3 – AUXILIARY AIR COMPRESSOR (KELLOGG-AMERICAN)
Disassembly of Pump 115
Fitting and Reassembly 116
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Section 4 – MAIN AIR COMPRESSOR
Rotary Vane Compressor (Allis-Chalmers) 119
1000 Hour Maintenance Check 119
4000 Hour Maintenance Check 120
Blade Protection in Idle Units 124
Rotor Alignment for Redowling 124
Rotor Field Redowling 125
Rotary Screw Compressor (AC Compressor Corp.) 126
Description 126
Coupling Alignment 127
Start-Up Procedure 127
Shutdown 128
Controls and Instruments 128
Reduced Unloaded Horsepower Feature (Optional) 134
Variable Volume Feature (Optional) 137
Lubrication System 138
Air Filters 145
Maintenance Schedule 146
CHAPTER 4 – DUST CONTROL
Section 1 – GENERAL MAINTENANCE
Drilling Platforms and Dust Curtains 153
Water Injection (Using Water Pump) 153
Water Injection (Pressurized) 153
Cold Weather Protection System 154
CHAPTER 5 – LUBRICATION
Section 1 – LUBRICATION PROCEDURES
General 155
Lubricant Cleanliness 155
Lubrication Points 155
Lubricant Benchmarks 156
Gearcase and Reservoir Capacities 156
Lower Works Lubrication 157
Mainframe Lubrication (Part 1) 158
Mainframe Lubrication (Part 2) 159
Mast Lubrication (Part 1) 160
Mast Lubrication (Part 2) 161
Mast Lubrication (Part 3) 162
Section 2 – LINCOLN AUTOMATIC SYSTEM
Troubleshooting Systems 163
Air Locks 163
Dirty Supply Lines 163
All Injectors Do Not Function Properly 163
After Venting, the Indicator Sterns on the Injectors
Do Not Return to Their Normal Position 163
Failure of Pump to Build Up Pressure 164
Sluggish Pump Operation 164
Slow Pressure Rise 164
Assembly of Tubing Compression Fittings 164
Principle of Operation – Pump Air Motor 164
Service of Lower Pumping Unit 166
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Lubrication 167
Installation, Operating, and Maintenance Instruction 168
Section 3 – TRABON AUTOMATIC SYSTEM
Locating Blockage in System 171
Terminology 171
Procedure 171
Torque Information in Foot Pounds 174
Section 4 – VANE TYPE MAIN COMPRESSOR OR BIT LUBRICATOR
Operation and Adjustment 175
To Start Lubricator 175
To Adjust Lubricator 175
Sight Feed Unit 175
Purging Oil From Pumping Unit 176
Care of Lubricator 176
CHAPTER 6 – TROUBLESHOOTING
General 177
Drilling 177
Rotary Drive Unit 179
Hoist-Propel Transmission 180
Mast 180
Main Air Compressor (Vane Type) 181
Main Air Compressor (Screw Type) 182
Auxiliary Air Compressor 185
Hydraulic System 186
Hydraulic Oil Cooler 187
Hydraulic Cylinder 187
Hydraulic Pump (Cylinder Circuit) 187
Hydraulic Hoist/Propel Pump 189
Hydraulic Hoist/Propel Motor 190
Hydraulic Chain Tensioner Circuit 190
Hydraulic Chain Equalizer Pump 190
Control Valves 191
Unloader Valves 192
APPENDICES
Appendix Al – GEAR INSPECTION
General lA
Appendix A2 – BOLT TORQUING
Torque Wrench Method 3A
Turn of the Nut Method 4A
Appendix A3 – PINION, BRAKE DRUM AND COUPLING INSTALLATION
Removal from Shaft 5A
Mounting on Shaft 5A
Appendix A4 – LUBE BENCHMARKS
Multipurpose Type Grease (MPG) 9A
Air Compressor (Vane Type) Lubricant (ACVL) lOA
Air Compressor (Piston Type) Lubricant (ACPL) llA
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Chain Drive Lubricant (CDL) 12A
Drill Pipe Thread Lubricant (DPTL) 13A
Multi-purpose Oil (MPO) 13A
Open Gear Lubricant (OGL) 14A
Regular Type Gear Lubricant 15A
Running Wire Rope Lubricant (RWRL) 19A
Hydraulic Oil (HYDO) 20A
Synthetic Hydraulic Fluid (PAO) 21A
Paraffinnic Base Petroleum Hydraulic Fluid 21A
Appendix A5 – RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRINCIPLE
STRUCTURES ON BLAST HOLE DRILLS
General 23A
Maintenance Welding 23A
Structural Materials 23A
Welding Electrodes 24A
Preheat Requirements 25A
Removal of Cracks 25A
Weld Groove Preparation 27A
Drill Pipe Welding 27A
Welding Technique 27A
Weld Inspection 27A
Repair of Broken Parts 27A
Methods of Repair of Cracks 27A
Appendix A6 – PREVENTATIVE MAINTENANCE CHECKLISTS
Level I Inspection 29A
Level II Inspection 33A
Level III Inspection 35A
Appendix A7 – SPECIAL DRAWINGS
Hoist-Pulldown Shaft 37A
Propel Shaft 37A
Idler Shaft 37A
Second Intermediate Pulldown Shaft 38A
First Intermediate Propel Shaft 39A
RH and LH Intermediate Propel Shafts 39A
Rotary Gearcase Shafts (4 7-R) 40A
Rotary Gearcase Shafts (45-R) 41A

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