CAT Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379433 – PDF DOWNLOAD

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CAT Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379433 – PDF DOWNLOAD

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CAT Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379433 – PDF DOWNLOAD

Language : English
Pages : 232
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379433 – PDF DOWNLOAD

FOREWORD:

• The purpose of this manual is to provide information concerning the general maintenance of the
  45-R rotary blast hole drill.
• The 45-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 a portion of the equipment necessary to
  propel the drill. The mainframe includes the hydraulic, main air and auxiliary air systems, the
  hoist-propel trans­ mission and the machinery house.-The machinery house encloses the majority of
  the mechanical equip­ ment necessary for the main and auxiliary air systems, 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, provides the operator’s station, and enclosed the majority of the controls necessary
  to operate the drill.
• 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 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 hazard 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 dis­ cussed.
• 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
  notdetailed in this manual.

TABLE OF CONTENTS:

CAT Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379433 – 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
Repair 7
Upper Rollers 8
Repair 9
Drive Tumblers 9
Repair 9
Take-Up Tumbler 10
Repair 10
Crawler Frames 11
Repair 11
Axles · 13
Repair 14
Propel Final-Drive Chains ‘” 14
Repair 14
Adjustment 14
Section 3 -MAINFRAME
Mainframe and Mast Support 17
Repair 17
Leveling Jacks 17
Repair 18
Machinery House 19
Repair 19
House Ventilation Fan and Filter ” 19
Walkways and Ladders 19
Operator’s Cab 19
Operator’s Seat 20
Operator’s Controls 29
Ventilation Unit 20
Hoist-Propel Gearcase ” 20
Repair 20
Removal and Installation of Gearcase 21
Gearcase Suspension 22
Hoist-Propel Gearcase Disassembly and Assembly 23
Hoist Shaft 23
BUCYRUS-ERIE COMPANY 1983
BI379433
Second Intermediate Shaft 25
First Intermediate Shaft 26
Idler Shaft 26
Propel Shaft 27
Propel Clutches 28
Repair 28
Hydraulic Motor Shaft 29
Electric Hoist-Propel Motor 30
Repair 30
Propel Machinery 31
Repair ‘ 31
First Intermediate Shaft 31
Second Intermediate Shaft 32
Propel Chain Adjustment 33
Hoist Brake 33
Adjustment ‘ ‘ 34
Repair 36
Auxiliary Reel Brake 37
Adjustment 37
Repair 38
Propel Brakes 39
Repair 40
Hoist-Auxiliary Reel Clutch Lever 40
Adjustment 41
Repair 41
Hydraulic Pulldown Motor Clutch Lever 42
Adjustment 42
Repair 43
Section 4 -MAST
l\tlast Structure 45
Repair 45
Mast Lock Pins 46
Repair 46
Mast Lock Latch 47
Repair 47
Rotary Gearcase 47
Adjustment 50
Repair (earlier style rotary gearcase) 51
Repair (latest style rotary gearcase) 52
Rotary Motor 54
Rotary Coupling 55
Repair 55
Retary Shock Sub 56
Repair 56
Rotary Guide Frame 57
Adjustment 58
Repair 59
Pulldown Chains 61
Adjustment 61
Repair 61
Pulldown Chain Equalizer ; 63
Repair 63
Tool Racks 65
Repair 65
Tool Wrenches 67
Repair 68
Back Braces 68
Repair 68
Adjustment 68
CHAPTER 2 – HYDRAULIC SYSTEM
Section 1 -SYSTEM OPERATION 71
Section 2 -GENERAL MAINTENANCE 75
Hydraulic System Cleanliness 75
Oil Requirements 75
Oil and Filter Changes 75
Weekly Maintenance Checks 76
Oil Reservoir Repairs 76
Unloader Valve Adjustment ‘” 77
Pressure Regulating (Relief) Valve Adjustment 77
Chain Equalizer Valve Adjustment 77
Section 3 – COMPONENT MAINTENANCE
Hydraulic Pump Overhaul 79
Disassembly 79
Cleaning 79
Inspection 79
Reassembly 80
Test Procedure 81
Main Valve Banks ‘” 81
General 81
Disassembly ” 81
Cleaning Inspection and Repair 83
Assembly 83
Hydraulic Pulldown Motor 83
Disassembly 83
Cleaning Inspection and Repair ” 85
Reassembly 85
Disassembly of Chain Equalizer Valve 85
Hydraulic Oil Cooler 86
Weekly Maintenance Check 86
1000 Hour Maintenance Check 86
Yearly Maintenance Check 86
CHAPTER 3 – AIR SYSTEMS
Section 1 -SYSTEMS OPERATION
General 87
Main Air System 87
Auxiliary Air System 87
Safety 87
” BUCYRUS-ERIE COMPANY 1983
BI379433
Section 2 – GENERAL MAINTENANCE
Main Air System ~ 91
General 91
Intake Air Filter – Box Type 91
Intake Air Filter – Tubular Type 91
Filter Replacement ” 92
Drive Belts 92
Belt Adjustment 92
Compressor Lubricator (Vane Compressor Only) 92
Feed Rate ‘ 93
Viscosity Grade 93
Lubricator Daily Maintenance Check 94
Lubricator Weekly Maintenance Check 94
Lubricator Service 94
Lubricator Priming 94
Compressor Radiato~ 94
Safety Valve Settings 94
Drill Pressure 95
Auxiliary Air System 95
Auxiliary Air Compressor 95
Miscellaneous Components 96
Unloader Check Valve Service 96
Tanner De-icer (optional) ‘” ” 96
Air Tanks 97
AirTankValves 97
Pressure Switch ‘ ‘ 97
Filter 97
Anti-Freezer 97
Maintenance Procedure for Air Dryer 98
Desiccant Canister Removal 98
Purge Valve Removal 99
Section 3 – AUXILIARY AIR COMPRESSOR (KELLOGG-AMERICAN)
Disassembly of Pump 101
Fitting and Reassembling ” ” 102
Section 4 – MAIN AIR COMPRESSOR
Rotary Vane Compressor (Allis-Chalmers) 105
1000 Hour Maintenance Check 105
4000 Hour Maintenance check 106
Blade Protection in Idle Units ‘109
Rotor Alignment for Redoweling 110
Rotor Field Redoweling ‘” ” ” 110
Rotary Screw Compressor (Allis-Chalmers) 111
Description III
Coupling Alignment 112
Start·Up Procedure ” ” 113
Controls and Instruments 114 (
Lubrication System ‘” ” 119
Air Filters 126
Maintenance Schedule 127
BI379433
Air Compressor (piston type) Lubricant (ACPL) 0 7A
Chain Drive Lubricant (CDL) 8A
Drill Pipe Thread Lubricant (DPTL) 0 9A
Multipurpose Oil (MPO) IDA
Open Gear Lubricant (OGL) 0 IOA
Regular Type Gear Lubricant (RGL) 0 12A
Running Wire Rope Lubricant (RWRL) 0 16A
Hydraulic Oil for Mining Machinery (HYDO) 0 00 17A
Appendix A5 -RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRINCIPAL
STRUCTURES ON BL<\ST HOLE DRILLS
General 19A
Maintenance Welding ‘” olgA
Structural Materials 0 19A
Welding Electrodes 20A
Preheat Requirements 0 22A
Removal of Cracks 22A
Weld Groove Preparation 22A
Drill Pipe Welding o 22A
Welding Technique 0 0 23A
Weld Inspection 23A
Repair of Broken Parts 23A
Methods of Repair of Cracks 0 23A
Appendix A6 – PREVENTIVE MAINTENANCE CHECKLISTS
Level I Inspection 25A
Level II Inspection 0 0 30A
Level III Inspection 32A
Appendix A7 – SPECIAL DRAWINGS
Hoist-Pulldown Shaft 33A
Propel Shaft 33A
Idler Shaft 0 0 33A
Hydraulic Motor Shaft 0 0 34A
Second Intermediate Pulldown Shaft o 34A
First Intermediate Pulldown Shaft 0 34A
First Intermediate Propel Shaft 0 0 35A
RH and LH Intermediate Propel Shafts ” 35A
Rotary Gearcase Shafts – Early Style 0 36A
Rotary Gearcase Shafts – Latest Style 0 o 36A
Rotary Unit Shipper Shaft 0 37A
Drive Tumbler Shaft 0 0 37A

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