MECHANICAL MAINTENANCE
Blast Hole Drill
BI379433
BUCYRUS-ERIE
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BI379433 (' (
BI379433 LOWER WORKS MAST
BI379433 ( (
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 man ual.
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 CA UTI 0 N' sand WARNIN G' s are not all-incl usi ve. It is im possible 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.
MACHINE SERIAL NUMBER
BI379433 FORE·WORD
BUCYRUS-ERIE COMPANY General Offices: South Milwaukee, Wisconsin, U.S.A.
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BI379433
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
TABLE OF CONTENTS
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 ( (
3-
BI379433 Tool Racks 65 Repair 65 Tool Wrenches 67 Repair 68 Back Braces. ........................................................................... .. 68 Repair 68 Adjustment 68 CHAPTER
HYDRAULIC
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 Reassem bly ......................................................................... .. 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 Main Air System 87 Auxiliary Air System ,.................................. 87 Safety 87 " BUCYRUS-ERIE COMPANY. 1983
2-
SYSTEM
CHAPTER
AIR SYSTEMS
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 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) , 7A Chain Drive Lubricant (CDL) ,, 8A Drill Pipe Thread Lubricant (DPTL) 9A Multipurpose Oil (MPO) .. ,,, , IDA Open Gear Lubricant (OGL) ,,, IOA Regular Type Gear Lubricant (RGL) 12A Running Wire Rope Lubricant (RWRL) 16A Hydraulic Oil for Mining Machinery (HYDO) 17A Appendix A5 - RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRINCIPAL STRUCTURES ON BL<\ST HOLE DRILLS General , 19A Maintenance Welding , '" , olgA Structural Materials 19A Welding Electrodes 20A Preheat Requirements , 0 22A Removal of Cracks 22A Weld Groove Preparation 22A Drill Pipe Welding o 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 A7- SPECIAL DRAWINGS Hoist-Pulldown Shaft 33A Propel Shaft ...........................•.............................................. 33A Idler Shaft 0•0 33A Hydraulic Motor Shaft 00 34A Second Intermediate Pulldown Shaft o 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 , o 36A Rotary Unit Shipper Shaft 37A Drive Tumbler Shaft 0 37A BUCYRUS-ERIE COMPANY, 1983
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CHAPTER 4- DUST CONTROL
BI379433
Section 1- GENERAL MAINTENANCE Drilling Platforms and Dust Curtains 133 Filter Air-Bag System 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 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 Lower Works , 143 Mainframe (Part 1) 144 rvIainframe (Part 2) , , 145 rvIast (Part 1) 146 Mast (Part 2) , , " 147 Mast (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-ERIECOMPANY, 1983
• 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
