CAT Bucyrus 45-R 47-R Blast Hole Drill Mechanical Maintenance Manual BI115929 – PDF DOWNLOAD

Technical Manual

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MECHANICAL

MAINTENANCE

FOR MACHINES WITH HYDRAULIC HOIST/PROPEL, , , ,

BUCYRUS-ERIE

t4Jrff D [fD . , Blast Hol;e Drill

This purpose of this manual is to provide information concerning the general maintenance of the BucyrusErie® 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 ofthe 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 heat buildup. 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 ofthe 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.

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 reserves the right, however, to continually improve its products. Therefore changes to the equipment herein may have been made that are not reflected in this manual.

MACHINE SERIAL NUMBER ________________

BUCYRUS-ERIE COMPANY

General Offices: South Milwaukee, Wisconsin, U.S.A.

LIT S364 BECOM 391

CHAPTERl

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 45-RJ47-R drills.

MAINTENANCE SCHEDULES AND REPORTS

Ideally, all maintenance should be approached from the preventive standpoint and on a regularly scheduled basis. Obviously, this approach keeps downtime to a minimum and results in reduced maintenance costs. To establish a preventive upkeep program, scheduled inspections' and an operator's daily report are the most useful tools available. Scheduled inspections should be conducted by the Mine Mechanical and Electrical Maintenance Departments since they are the most qualified. Either department should generate a certain amount of paper work such as inspection records that become a part of the mine's permanent file on the machine. The inspection records should be explicit, complete, and cover every part of the. machine. Each machine operator should complete a daily record of the machine's 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 potentially 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 considered during 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 circumstances?

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 be 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 have 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 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 the manufacturer for design improvement necessary?

4. What costs were incurred in downtime, parts, tools and labor?

5. Could the problem have been prevented by prior action?

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 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 to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of these 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. In-operation deficiencies should be carefully investigated. It should be determined if a safety problem exits. Remember, maintenance is vital to safe operation. It should be performed systematically by competent personnel.

From an economic standpoint, 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 as gear tooth inspection and re-

placement, which require machine shut down. However, many support duties can be safely and effectively handled at shift change when the machine is still activated.

Automatic lubrication systems function throughout the operational cycles of the machine. These systems release premeasured lubricant which lengthen the wear life of the machinery units. Other parts of the machinery may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator's hand at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.

A repair or maintenance job on equipment 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 position before 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

• Set all brakes

• De-energize control functions and tag.

• Open circuit breakers and tag.

• Do whatever else is necessary to prevent accidental movement of the machine.

NOTE: If power is essential 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 repair work is being done.

Prior to undertaking 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 in the "off' position and tagged. The lock and tag should be removed only by the maintenance people who installed them.

During all phases of maintenance, use extreme caution when working near electrical equipment. N ever work near exposed, energized high voltage connections.

Approved protection equipment such as gloves and insulated hooks or tongs should always be used when high voltage electrical cables are handled. Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers and switches.

While performing maintenance, the awkward positions assumed often increase injuries due to handling heavy parts. As a precautionary measure, use mechanical handling equipment whenever 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.

A CAUTION: Many of the components of a the 45/47-R 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.

CHAPTER 1

MECHANICAL MAINTENANCE SECTION 2 - LOWER WORKS

eRAWLER BELTS

The crawler belts should be inspected frequently to prevent an unexpected breakdown (Figure 1.)

Check the links for cracks, worn lugs, elongated link pin bores and other damage. Minor cracks in the link do not constitute a major problem. However, cracked links should be repaired by welding or replaced at a convenient time. Links with broken or worn drive lugs should be replaced at the earliest convenient time as they can cause the belt to ride off the rollers or take-up tumblers. Links with elongated pin bores should be checked carefully for cracks at the pin lugs and replaced if badly worn or cracked. Bent, broken or badly worn link pins should be replaced.

ADJUSTMENT

The crawler belts should be so adjusted that the sag in the belts should be approximately 3"-5" at the center points between the upper rollers (Figure 2.)

Adjustment of the crawler belts is accomplished at the take-up tumbler end ofthe belts. The takeup tumblers are mounted on shafts which are clamped in bearing blocks. The bearing blocks are bolted to the crawler frames. Shims placed ahead or behind the bearing blocks position the bearing block and tumbler to provide the desired belt tension (Figure 3.)

To Adjust Belt Tension:

1. Take weight of machine off crawlers using leveling jacks. Block machine in raised position.

2. Remove the tumbler shim guards from the inside and outside of the crawler frame.

3. Loosen the jam nuts and full nuts securing the bearing blocks to the crawler frame on both sides. Loosen the nuts only enough to allow the bearing block to slide on the crawler frame.

4. Position suitable hydraulic jacks behind each of the bearing blocks.

5. Remove several shims from in front of the bearing blocks. LOWER WORKS

FIGURE 1

FIGURE 2

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