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.
BI379559
MACHINE
BUCYRUS-ERIE COMPANY General Offices: South Milwaukee, Wisconsin, U.S.A.
SERIAL NUMBER-----------------------
BI379559 ( (
BI379559
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
TABLE OF CONTENTS
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
CHAPTER 3 - AIR SYSTEMS
BI379559 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
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
CHAPTER 4 - DUST CONTROL
BI379559
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
CHAPTER 6 -
APPENDICES
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
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 181 182
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 ......................................... 7A 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 37A o BUCYRUS-ERIE COMPANY. 1983
BI379559 ( (
CHAPTER 1
SECTION 1 - MAINTEN.t-\NCE 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 -15-R drill.
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. Schedule 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 \Vorked. 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?
0. Is the problem of a repetitive nature?
6. By leaving the repairs to a later date, •.vill 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 be scheduled?
6. Will there be aQ.equate 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?
BI379559
• BUCYRUS-ERIE COMPANY, 1983 1
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