CAT Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379559 – PDF DOWNLOAD

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CAT Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379559 – PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379559 – PDF DOWNLOAD

Language : English
Pages : 230
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379559 – 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 transmission
  and the machinery house. The machinery house encloses the majority of the mechanical equipment
  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 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 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 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:

CAT Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379559 – PDF DOWNLOAD

CHAPTER 1 -MECHANICAL MAINTENANCE
PAGE
Section l- 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
A djustment 5
Link Replacement 6
Belt Replacement 7
Lo,ver Rollers 7
Repair 7
Upper Rollers 8
Repair 9
Drive Tumblers 9
Repair 9
Take-Up Tumbler 10
Repair 10
Cra\vler Frames 11
Repair 11
A xles 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
BI379559
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 l\tlachinery 31
Repair 31
First Intermediate Shaft 31
Second Intermediate Shaft 32
Propel Chain Adjustment 33
Hoist Brake 33
A djustment 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’v1ast Structure 45
Repair 45
l’vlast Lock Pins 46
Repair 46
l\tlast Lock Latch 47
Repair 47
Rotary Gearcase 4 7
Adjustment 50
Repair (earlier style rotary gearcase) 51
Repair (latest style rotary gearcase) 52
Rotary Motor 54
Rotary Coupling 55
Repair 55
R0tary 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
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Tool Rack s 65
Repair 65
Tool \Vrenches 67
Repair 68
Back Braces 68
Repair 68
A djustment 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
l Ylain Valve Banks 81
General 81
Disassembly 81
Cleaning, Inspection and Repair 83
A ssembly 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
1\tlain Air System 87
Auxiliary Air System 87
Safety 87
“BUCYRUS-ERIE COMPANY 1983
BI379559
Section :2- GENERAL iYIAINTENANCE
ivlain Air System
General
91 (
91
Intake Air Filter- Box Type 91
Intake Air Filter- Tubular Type 91
Filter Replacement 92
Drive Belts 92
Belt A djustment 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 Radiator 94
Safety Valve Settings 94
Drill Pressure 95
A uxiliary Air System 95
Auxiliary Air Compressor 95
Miscellaneous Components 96
U nloader Check Valve Service 96
Tanner De-icer (optional) 96
Air Tanks ········· 97
Air Tank Valves 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 t09
Rotor Alignment for Redoweling 110
Rotor Field Redoweling 110
Rotary Screw Compressor (Allis-Chalmers) 111
Description 111
Coupling Alignment 112
Start-Up Procedure 113
Controls and Instruments 114
Lubrication System 119
Air Filters 126
Maintenance Schedule 127
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CHAPTER 4 – DUST CONTROL
Section 1- GENERAL MAINTENANCE
Drilling Platforms and Dust Curtains 133
Filter Air-Bag System (Amerpulse) 133
Daily Maintenance Checks 133
Monthly Maintenance Checks 133
Six Month Maintenance Checks 134
Water Injection (using water pump) 134
Water Injection (pressurized) 134
Cold Weather Protection System 135
Section 2- MAINTENANCE OF AMERPULSE”
Operating Principles 137
Filter Tube Installation 137
Printed Circuit Timer Test 137
Solenoid Valve Test 139
Pulse Recommendations 139
Hopper Vibrator 139
CHAPTER 5- LUBRICATION
Section 1- LUBRICATION PROCEDURES
General 141
Lubricant Cleanliness 141
Automatic System Lubrication Points 141
Manual Lubrication Points 141
Lubricant Benchmarks 142
Lubrication Charts 142
Gearcase and Reservoir Capacities 142
Lo\ver Works 143
Mainframe (Part 1) 144
Mainframe (Part 2) 145
Mast(Part1) 146
Mast (Part 2) 147
l’vlast (Part 3) 148
Section 2- LINCOLN AUTOMATIC SYSTEM
Troubleshooting Systems 149
Air Locks 149
Dirty Supply Lines 149
All Injectors Do Not Function Properly 149
After Venting, the Indicator Stems on the Injectors
Do Not Return to Their Normal Position 149
Failure of Pump to Build Up Pressure 150
Sluggish Pump Operation 150
Slow Pressure Rise 150
Assembly of Tubing Compression Fittings 150
Principle of Operation- Pump Air Motor 150
Service of Lower Pumping Unit 152
Lubrication 153
Installation, Operating, and Maintenance Instructions 153
¢ BUCYRUS·ERIE COMPANY 1983
BI379559
Section 3- TRABON AUTOMATIC SYSTEM
Locating Blockage in System 157 (
Terminology 157
Procedure 157
Torque Information in Foot Pounds 160
Section 4- VANE TYPE MAIN COMPRESSOR LUBRICATOR OR BIT LUBRICATION
Operation and Adjustment 161
To Start Lubricator _ 161
To Adjust Lubricator 161
Sight Feed Unit 161
Purging Oil From Pumping Unit 161
Care of Lubricator 162
CHAPTER 6 – TROUBLESHOOTING
Section 1 -TROUBLESHOOTING
General 163
Drilling 164
Rotary Drive Unit 166
Hoist-Propel Tnlnsmission 166
Mast 167
Main Air Compressor (vane type) 167 (
Main Air Compressor (screw type) 170
Auxiliary Air Compressor 173
Hydraulic System 174
Hydraulic Oil Cooler 175
Hydraulic Cylinder 175
Hydraulic Pump 176
Hydraulic Pulldown Motor 178
Pressure Regulating and Pulldown Pressure Relief Valves 179
Hydraulic Chain Equalizer Pump 180
Control Valves 180
Unloader Valves 181
Amerpulse~· 182
APPENDICES
Appendix A1 -GEAR INSPECTION 1A
Appendix A2- BOLT TORQUING
Bolt Torque Values for Static Joints Bulletin 6-82-1
Appendix A3- PINION AND COUPLING INSTALLATION
Removal For Motor Shaft 3A
Mounting Pinion or Coupling Shaft 3A
Appendix A4- LUBE BENCHMARKS
Multipurpose Type Grease (MPG) 5A
Air Compressor (vane type) Lubricant (ACVL) 6A
BI379559
Air Compressor I piston type) Lubricant (ACPLl 7 A
Chain Drive Lubricant (CDL) SA
Drill Pipe Thread Lubricant ( DPTLl 9A
i\ Iultipurpose Oil (MPO) lOA
Open Gear Lubricant (OGLl lOA
Regular Type Gear Lubricant (RGLl 12A
Running Wire Rope Lubricant (RWRU 16A
Hydraulic Oil for Mining Machinery (HYDO) 17 A
Appendix A5- RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRINCIPAL
STRUCTURES ON BLA ST HOLE DRILLS
General 19A
Maintenance Welding · 19A
Structural Materials 19A
Welding Electrodes 20A
Preheat Requirements 22A
Removal of Cracks 22A
Weld Groove Preparation 22A
Drill Pipe Welding 22A
Welding Technique 23A
Weld Inspection 23A
Repair of Broken Parts 23A
Methods of Repair of Cracks 23A
Appendix A6- PREVENTIVE MAINTENANCE CHECKLISTS
Level I Inspection 25A
Level II Inspection 30A
Level III Inspection 32A
Appendix A 7- SPECIAL DRAWINGS
Hoist-Pull down Shaft 33A
Propel Shaft 33A
Idler Shaft 33A
Hydraulic Motor Shaft 34A
Second Intermediate Pulldown Shaft 34A
First Intermediate Pulldown Shaft 34A
First Intermediate Propel Shaft 35A
RH and LH Intermediate Propel Shafts 35A
Rotary Gearcase Shafts – Early Style 36A
Rotary Gearcase Shafts- Latest Style 36A
Rotary Unit Shipper Shaft 37A
Drive Tumbler Shaft 37 A

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