CHAPTER 1 MECHANICAL MAINTENANCE
SECTION 1- MAINTENANCE PROCEDURE GENERAL
This section of the manual describes those aspects of preventive maintenance such as scheduled reports and safety precautions as they pertain to the 35HR drill.
MAINTENANCE SCHEDULE AND REPORTS
Ideally, all maintenance should be approached from the preventive stand point and on a regularly scheduled basis. Obviously, this approach keeps downtime to a minimum and results in reduced maintenance costs. To establish a preventive up-keep program, scheduled inspections and an operators daily report are the most useful tools available. Schedule inspections should be conducted by the Maintenance Department since is the most qualified. The department should generate a certain amount of paper work such as inspection records that become a part of the mines permanent file on the machine. The inspection records should be explicit, complete, and cover every art of the machine. Each machine operator should complete a daily record of the machines performance. This record should include time worked, time down, reasons for all delays, and observations on any unusual conditions encountered during operation. From these records, items that can potencially cause machine downtime can be corrected or prevented immediately, or scheduled for a future date when the machine availability can be coordinated with the other mine activities.
Each problem should be thoroughly reviewed and evaluated before scheduling any maintenance or repair. The following points should be consideredduring the evaluation.
1- Is the problem one of normal wear?
2- Is the problem caused by machine application?
3- Is the problem a result of operator error?
4- Is the problem a result of unavoidable ci rcumstances?
5- Is the problem of a repetitive nature?
6- By leaving the repairs to a later date, will any other component be affected?
7- Can repairs be accomplished immediately?
8- Will the cost of repairs immediately rather than later worthwhile?
9- How long will the machine be down?
Once maintenance or repair has been scheduled, take the following points into consideration to minimize downtime and expense.
1- Are all tools and equipment needed to accomplish maintenance or repair available on the job, and are they in good repair?
2- Are all replacement parts on hand and readily available.
3- Is replacement of auxiliary parts, such as seals and bearings, necessary to accomplish repair, and they been ordered?
4- Is all disassembly and reassembly data available?
5- Have repair crews been scheduled.
6- Will there be adequate supervision on hand for the repair crews?
7- Has the manufacturer been consulted for Service or Engineering assistance?
8- How long will the machine be down?
Once repair has been accomplished, the problem, the problem should again be reviewed with the following things in mind.
1- Was the cause of the problem permanently corrected or just patched?
2- What guarantee is there the same problem will not occur again?
3- Is consultation with manufacturer for design improvement necessary?
SAFETY GENERAL
The importance of overall safety in the maintenance of mining equipment should always be emphasized; excavating operations may involve a variety of hazardous conditions. Many critical
3 BI005557
components are subject to wear and other deterioration which limits their useful life; thus they are expendable. When new, all such parts have a built-in reserve strength against unknown factors and reasonable loss of durability from gradual wear. If however, inspection and adjustment are neglected, these parts eventually reach a condition where they become a safety problem. Similarly, failure to replace various mechanisms to insure proper performance of the machine also constitutes a safety problem. Study this manual carefully and follow all recommended procedures. Supervisor, operators and maintenance men should continuously follow safe practices.
IN-OPERATION MAINTENANCE
Safety requirements dictate that all machines in active service be inspected at regular intervals for proper adjustment of operating mechanism, excessive wear of components, system cleanliness and any other defects. Inoperational deficiencies should be carefully investigated. It should be determined if a safety problem exists. Remember maintenance is vital to safe operation. It should be performed systematically by competent personnel.
From an economic stand point, it is advisable to perform as much of the upkeep as can be safely accomplished while the machine is running. Obviously, there are some maintenance procedures, such a gear tooth inspection and replacement, which requires machine shut down. However, many support duties can be safely and effectively handled at shift change when the machine is still activated.
Parts of the machinery may be manually lubricated in a safe manner though extended grease or oil fittings designed to keep operators hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.
A repair or maintenance job is not complete until guards, plates and other safety devices have been replaced before the equipment is restored to operation.
PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK
The operator must be sure the equipment is in a safe positionbefore repairs or adjustments are made. The machine should
not be endangered by falling rock or a yielding support surface. Before beginning repair or adjustment, the operator shall:
• Secure the rotary drive unit and tool string.
• Turn off all control functions and tag.
• Do whatever else is necessary to prevent accidental movement of the machine.
NOTE: If power isessential to the repair, it should only be energized when all personnel are clear of electrical and mechanical hazards. The power should only be energized during the required period and not when the repair work is being done.
Prior to undertake any work, maintenance personnel should notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the starting controls should be locked "off' position and tagged. The lock and tag should be removed only by the maintenance people who installed them.
While performing maintenance, the awkward positions assumed often increase injuries due to handling heavy parts. As a precautionary measure, use mechanical handling equipment when ever possible. The mining foreman can facilitate safer and easier maintenance work by providing blocking materials. Service crews should have a fundamental knowledge of lifting practices so their knees and legs are used rather than their backs.
! caution: Many of the components of the 35HR drill are heavy, bulky items. Extreme caution should be used when lifting. Personnel should be certain of the weights of components before attempting to lift them, either manually or with some lifting device. Follow all applicable safety rules when using cranes or other lifting equipment. Be sure of the load, lifting height and radius, and capacity of the lifting device before lifting. Failure to follow all applicable safety rules when lifting can cause serious or fatal injury to personnel.
4 BI005557
GENERAL
CHAPTER 1
MECHANICAL MAINTENANCE SECTION 2- UNDERCARRIAGE
The lower works consists of two crawler units bolted to the mainframe. The bolts should be checked periodically for tightness. Refer to the Disassembly & Assembly part for torque procedure. Each crawler unit is made up of a side frame to which mounted the drive unit, idler unit, crawler belt upper roller units, crawler belt lower support roller units and crawler belt. The brakes are part of the drive units. The drive motors also are covered under this section of the manual.
NOTE: The tools part number on undercarriage section were provided by Caterpillar.
UNDERCARRIAGE
Disassembly and Assembly
BUCYRUS 35HR Blast hole drill
Track Carrier Rollers
Remove & Install Track Carrier Rollers
!ools Needed
IThe grease in the track adjusting cylinder is under high pressure. Grease coming out of the relief valve of the track adjuster, which is under high pressure, can penetrate the body causing personal injury or death. When loosening the tension on the track, loosen the relief valve only one turn. Do Not visually inspect the relief valve to see if grease is being released from the track adjuster. Instead, watch the track to see if it loosens, if the track does not loosen after opening the relief valve, move the machine forward and backward to release the tension.
5 BI005557
2. Release the tension on the track. Loosen relief valve (1) only one turn. If the track does not loosen after opening the relief valve, move the machine forward and backward until the tension is released.
3. Loosen bolt (2) that holds track carrier roller (3) to the mounting bracket on the undercarriage frame assembly.
4. Put wood blocks and Tool (A) under the track assembly, as shown. Lift the track assembly off of the track carrier roller. Using two persons, remove track carrier roller (3). The weight of the track carrier roller is 23 kg (50 Ib). NOTE: The following steps are for the installation of the track carrier roller.
5. Be sure the shaft of the track carrier roller and the bore in the mounting bracket on the undercarriage frame assembly is clean and free of dirt.
6. Put the track carrier roller in position in the mounting bracket. Adjust the carrier roller until distance (B), the distance between the outside face of the mounting bracket and the carrier roller is 7.0 ± 0.5 mm (.28 ± .02 in).
7. After adjusting the position of the carrier roller in the mounting bracket, tighten bolt (2).
C47751 P1*
6 BI005557
8. Be sure the carrier roller rotates smoothly by hand. Slowly lower the track assembly on to the carrier roller with Tool (A).
9. Tighten the tension of the track. Refer to the topic "Tracks" in the "Operation & Maintenance Manual."
1.01 Disassemble & Assemble Track Carrier Rollers
1P-051 0 Driver Group
9U-5985 Seal lnstalle r 1
8T-5096 Dial Indicator Group 1
Start By:
a. remove track carrier rollers
Fluid Spillage Containment
Care must be taken to ensure that the fluids are contained during performance of the inspection, the maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to the "Tools And Shop Products Guide, NENG2500" the tools and the supplies suitable to collect and contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and mandates.
1. ,..horoughly clean the the track carrier roller prior to disassembly .
2. the carrier roller in a suitable container for disposal. The capacity of the track carrier roller is 120 ± 5 ml (4.08 ± 0.17 oz).
3. Remove three socket head bolts (1) and cover (3) from the track carrier roller
4. Remove O-ring seal (4) from cover (3).
Tools Needed AB C
1
:::::::::::::::::: ::::::::::::::::::::::::::::::: »-(,> ••••• !! ••••• -
::::: :::::::::::.. :::::::::: :::::::::: : : :: ::: ::::::: :::: :.::::::::::::: ••••••••••••••••• •••••••••••••••• :.:.:.:':.:.:.:.:.:.: .:.:.:.:.: '.:.:.: .:.:':.: .:.:. :.. ::.:.'.'
7 BI005557
.;.c;. .:.
."'-'..-" .
5 socket head bolts (5) and (6) and retainer (7) from the end of the shaft assembly
<:::::::::::< <:: .. •••••••••••. ... . .. , • '
6. Carefully remove shaft assembly (8) from the track carrier roller.
(!)•. ' .•. ... :w. :::'.' .1 ·iit.
8. Remove Duo-Cone seal (10) from the shaft assembly (8).
8 BI005557
9. Measure distance (X) on the shaft assembly. Record this dimension for assembly purposes. Using a press, push shaft (8) out of collar (11). Remove the O-ring seal from inside the collar.
10. Remove bearings (12) and (13) from the track carrier roller.
NOTE: The following steps are for the assembly of the track carrier rollers.
11. Thoroughly clean all parts of the track carrier roller prior to assembly.
NOTE: Do Not reuse bearings (12) and (13). Use new parts for replacement.
. ::::::::::::::::::::c: :::::::::::::::::::::
.(... .. -:::>.::::::::>.::: . ,.'::::::::::::<::::: ,:,"'" '<:):m 9 BI005557
14. Check the condition of the O-ring seal used in collar (11). If the O-ring seal is damaged, use a new part for replacement. Install the O-ring seal in the collar. Put clean oil on the O-ring seal.
15. Using a press, install collar (11) on shaft (8) until dimension (X) is 129.2 ± 0.2 mm (5.09 ± .008 in).
16. Determine shaft end playas follows:
NOTE: Do Not install the Duo-Cone seals in the track carrier roller or collar (11) at this time.
a. Install shaftassembly (8) in the track carrier roller without Duo-Cone seals.
b.Install retainer (7) and socket head bolts (5) and (6) on the end of shaft assembly (8).
c. Use Tooling (C) to measure the end play of shaftassembly (8). The end play of the shaft assembly must be 0.20 to 0.75 mm (.008 to .030 in). Bearing (12) controls the amount of shaft end play.
d. Disassemble the track carrier roller, but Do Not remove collar (11) from shaft (8).
NOTICE
Refer to the topic "Assembly And Installation Of Conventional Duo-Cone Seals" in this module.
NOTE: The rubber seal and all of the surfaces that make contact with the seals must be clean and dry. After the installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals
17.lnstaIlDLJo-Con8seal (10) in collar (11) with Tool (8).
in the track carrier roller (side without three threaded holes) with
•: :: .,
< :':-:- :-:-.-: :-:-:-:."-:-:-:-:-:.:-:-:-:-:-:-:-:-:.:-:-:.:-:-:-:-:
10 BI005557
19. Carefully install shaft assembly (8) in the track carrier roller. Install retainer (7) and socket head bolts (5) and (6) ,
20. Check the condition of a-ring seal (4) used on cover (3). If the a-ring seal is damaged, use a new part for replacement. Put clean oil on a-ring seal (4), and install it on cover (3)
21. Install cover (3) on the track carrier roller and three socket head bolts (1) that hold it.
22. Put the track carrier roller in a vertical position. Fill the track carrier rollerwith 120 ± 5 ml (4.08 ± 0.17 oz) of clean SAE 30 oil.
23. Apply Pipe Sealant on the threads of plug (2). Install plug (2).
End By:
a. install track carrier rollers
Track Rollers
Se(fao 1.02 Remove & Install Track Rollers
85-7640 Stand
8S-76t 1 Tube 2
8$-.7615 Pin 2
FT-131 0 Track Roller Lifting Fork 1
NOTE: There is a track guide on each side of the machine. The procedure which follows is for the removal and the installation of the track roller with the guide.
1. Put the machine on a flat level floor.
---,,-,,-----------_................................. ---
..•..•••.•.•.•••.•.•••.•.•..••.•....'..........I ....•.•....................... .I - '. , .••...•.. -•'•..••.•...•.•- .' •.
•.•••••••.•••••••••••• >:<>::-:.; ... :...•...••••••••••••••••••••••••••••••••••••.•..
Tools Needed AB
2
11 BI005557
The grease in the track adjusting cylinder is under high pressure. Grease coming out of the relief valve of the track adjuster, which is under high pressure, can penetrate the body causing personal injury or death. When loosening the tension on the track, loosen the relief valve only one turn. Do Not visually inspect the relief valve to see if grease is being released from the track adjuster. Instead, watch the track to see if it loosens, if the track does not loosen after opening the relief valve, move the machine forward and backward to release the tension
•
2. Release the tension on thetrack. Loosen the relief valve for the track adjuster only one turn. If the track does not loosen after opening the relief valve, move the machine forward and backward until the tension is released.
NOTE: Adjust height of Tooling (A) so when it is installed under the frame of the machine, there is enough clearance provided for the removal of anyone of the track rollers.
3. Lift the side of the machine, and install Tooling (A) under the frame, as shown.
4. Loosen the four bolts that hold track guide (1) to the undercarriage frame assembly. Do Not remove the bolts at this time.
5. Fasten a hoist on Tool (8), and put in position under track guide (1), as shown. Remove the bolts that hold the guide; then remove the guide.
i ... ............... '.' <<:':':':':' :.:.:.:":.: : ,., ::::::::;::::::::: ::::::: :::::::;:)
12 BI005557
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
