CAT Bucyrus-Erie 45-R BLAST HOLE DRILL OPERATOR’S MANUAL BI005448 – PDF DOWNLOAD

Technical Manual

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purpose maintenance 45-R rotary

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.

drill. The mainframe includes the main air and air the transpressurized minimize cab, mounted the mainframe, provides the station, and enclosed the majority of chapters, contents

This manual consists of six chapters, each divided into sections. A table of contents is located in the front of the manual.

this manual the words WARNING and NOTE bold face by safety symbol A injury occur proper procedures not operation use extreme

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 hazard to the machine or its the are not equipment damage. is used point give additional information concerning the procedure being dis-

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 ON's and WARNIN G' s are not all- inclusi ve. 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.

These and all- inclusi is impossible for Bucyrus-Erie know, evaluate, a be and of the hazardous of each method. is by Bucyrus-Erie Company to satisfy procedure not own or cause or effort has been made make this manual complete and accurate possible the time of machine manual.

MACHINE SERIAL NUMBER

BUCYRUS-ERIE COMPANY

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

TABLE OF CONTENTS

APPENDICES

CHAPTER 1

SECTION 1- MAINTENANCE PROCEDURE

SECTION 1 - MAINTENANCE PROCEDURE

GENERAL

aspects as and safety precautions they pertain

This section ofthe manual describes those aspects of preventive maintenance such as scheduled reports and safety precautions as they pertain to the 45-R drill.

MAINTENANCE SCHEDULES

MAINTENANCE SCHEDULES AND REPORTS

Ideally, all maintenance should be approached downtime to a minimum and results reduced costs. To keep program, inspections an operdaily the useful tools availsince are the most amount of work such as records the machine. The records should be operator complete a record should include time worked, time down, reasons on any unusual conditions encountered during operation.

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 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 preven ted immedia tely, or sched uled for a future da te 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?

maintenance The should be considered 1. 2. Is the caused machine 3. problem operator error?

4. problem

4. Is the problem a result of unavoidable circumstances?

5. Is

5. Is the problem of a repetitive nature?

6. By leaving repairs a any other be affected?

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?

7. Can be later be worthwhile?

How

9. How long will the machine be down?

Once maintenance or has been scheduled, take the into consideration to

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?

l. Are equipment accomplish maintenance repair available as seals and bearings, accomplish and have been ordered?

4. Is all disassembly and reassembly data available?

5. Have repair crews be scheduled?

6. Will there be adequate supervision on hand for the repair crews?

7. Has the manufacturer been consulted for Service or Engineering assistance?

4. disassembly reassembly repair be scheduled? hand for the repair Has Service 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?

l. Was corrected or guarantee will not occur

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 builtin 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 continously follow safe practices.

IN-OPERATION MAINTENANCE

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 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 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.

and any

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 andany other defects. In-operation 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 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 a gear tooth inspection and replacement, which require machine shut down. However, many support duties can be safely and effectively handled at shift change when the machine is still activated.

should are clear electrical and mechanical should

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. Never work near exposed, energized high voltage connections.

position

are and switches.

handled. Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers, and switches.

While performing positions assumed often increase due to

handling equipment ever can maintenance by providing crews a fundamental knowledge of lifting practices

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.

ACAUTION: of the of are

Personnel should be the components them, manually

using cranes or lifting equipment.

and of the device lifting. all applicapersonnel.

CAUTION: Many of the components of the 45-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.

SECTION 2- LOWER WORKS

CRAWLER 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 inspected frequently prevent or at convenient time. Links with at ride off the rollers take-up tumblers. Links Bent, worn pins should be replaced. inches the center between the

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

To Adjust Belt Tension:

1. leveling jacks. Block machine in raised posi-

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.

Adjustment ofthe crawler belts is accomplished

tumblers are mounted on shafts which are clamped in the crawler frames. Shims placed ahead or behind

Adjustment ofthe crawler belts is accomplished at the take-up tumbler end of the belts. The take-up 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).

3. Loosen the nuts and full nuts the bearing blocks the crawler frame only enough allow the bearing block slide the crawler

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.

Position suitable hydraulic jacks behind each

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

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

3"TOS"

FIGURE 2

6. Actuate the hydraulic jacks to push the bearing blocks forward to provide the desired belt tension. Make sure the bearing blocks slide straight on the crawler frame and do not become cocked.

7. Insert sufficient shims behind the bearing blocks to maintain the adjustment. Several different thicknesses of shims are provided. Be sure that the shims are the same thickness behind each bearing block.

8. Remove the hydraulic jacks.

6. Actuate the to ing to provide sure bearing blocks slide straight on the crawler frame and do become sufficient shims behind the bearing to maintain different thicknesses of shims are provided. the behind each bearing block. Remove

9. Tighten the full nuts clamping the bearing block to the crawler frame. Tighten the jam nuts to secure the full nuts.

Tighten the full clamping the bearing to the crawler Tighten the nuts to secure the full nuts.

10. Reinstall the shim guards on the crawler frame.

11. Repeat the procedure for the other crawler belt if necessary.

10. Reinstall the shim guards on frame. for the other belt if necessary.

12. Remove and lower machine.

12. Remove blocking and lower machine.

(Figure 4)

LINK REPLACEMENT (Figure 4)

To replace a link in the crawler belts:

replace link crawler

1. Propel the machine to position the defective link in an accessible position near one end of the crawler.

Propel machine to defective link accessible near one end of the

2. Remove the tension from the belt by removing all of the tensioning shims from behind the take-up tumbler bearing blocks. Refer to the CRAWLER BELT ADJUSTMENT for details of this procedure.

2. Remove the tension from the belt removing all behind the take-up bearing to the CRAWLER BELT ADJUSTMENT for details of this procedure.

3. Secure the belt against unwanted movement.

4. Attach a suitable lifting device to the defective link. Part the belt at the defective link by removing the two link pins securing the link to one end of the belt.

3. Secure the belt unwanted movement. Attach suitable lifting device the defecPart at defective by link pins link to of belt.

5. With the lifting of with defective to ground.

5. With the lifting device lower the end of the crawler belt with the defective link to the ground.

6. from replacement on the end belt resting

6. Remove the defective link from the belt.

7. Install the replacement link on the end of the belt resting on the ground.

FIGURE 4

BELT

FRAME EQUALIZER AXLE 5. HYDRAULIC JACK

FIGURE

8. U sing the lifting device lift the end of the belt into position to insert the remaining link pins.

9. Insert the link pins and secure with cotter pins.

10. Remove any equipment securing the belt against movement.

8. sing the lift the position to link pins. pins. Remove the belt against movement. tension as described in CRAWLER ADJUSTMENT topic

11. Readjust belt tension as described in the CRAWLER BELT ADJUSTMENT topic of this manual.

BELT REPLACEMENT (Figure 5)

REPLACEMENT 5)

Although belt replacement is required infrequently, there are times when it is necessary. To replace a belt, first propel the machine to firm, flat, level ground.

are times necessary. To replace first the machine to ground.

1. tension the removing blocks as described the topic BELT

1. Remove tension from the belt by removing the shims from behind the take-up tumbler bearing blocks as described in the topic CRAWLER BELT ADJUSTMENT.

2. Part the belt at a point midway between the upper rollers by removing the link pins.

2. Part the belt at a between the upper by removing link pins.

3. Attach a suitable lifting device the ends of the belt and end belt off the crawler frame and lay it the ground.

3. Attach a suitable lifting device to the ends of the belt and drag and lift each end of the belt off the crawler frame and lay it on the ground.

4. the machine leveling jacks, raise the to the old to be from underneath of the crawler frame. Securely the in

4. Using the machine leveling jacks, raise the machine sufficiently to allow the old belt to be dragged from underneath of the crawler frame. Securely block the machine in this position.

5. Using a suitable vehicle and rigging, drag the old belt from underneath of the crawler frame.

5. a and the old underneath of the crawler

SEPARATE MIDWAY UPPER ROLLERS

6. new flat on the frame.

6. Assemble the new belt and lay it flat on the ground near the crawler frame.

Using a and rigging, drag new belt of the crawler frame that the roller path in the ofthe belt the drive belr and take-up tumbler.

7. Using a suitable vehicle and rigging, drag the new belt underneath of the crawler frame so that the roller path in the center of the belt is aligned with the lower rollers, drive tumbelr and take-up tumbler.

8. Remove the blocking and slowly lower the machine until the crawler rollers and tumblers are resting on the belt.

9. Using a suitable lifting device, lift the ends of the belt into a position to insert the link pins.

8. the and are on the belt. suitable the the belt into position insert the link pins.

10. Insert the link pins and cotter pins to complete the belt.

10. the and pins to plete the belt.

11. Readjust the tension as topic

11. Readjust the belt tension as described in the topic CRAWLER BELT ADJUSTMENT.

LOWER ROLLERS

LOWER ROLLERS

Inspect the lower rollers for cracks and damage that can impair normal tracking of the crawler belts (figure 6).

Once a month raise the machine with the leveling jacks to allow inspection of the rollers. Block the machine in a raised position. Using a suitable lever, check the clearance ofthe roller bushing by lifting and then lowering the roller. Replace the bushing if the clearance is excessive.

the lower rollers for cracks and damage impair tracking crawler belts a raise jacks allow inspection of the rollers. Block the machine raised position. lever, check the clearance ofthe roller bushing by lifting Replace bushing if the clearance is excessive.

REPAIR

The most common problem encountered with lower rollers is bushing wear. However, over a period of time, the rollers will wear and possibly develop cracks. The cracks may be repaired by gouging and welding. Follow the welding instructions in the APPENDIX.

REPAIR most problem lower is However, a period possibly develop The cracks may by gouging and welding. Follow the welding instructions in APPENDIX.

SEPARATE MIDWAY BETWEEN UPPER ROLLERS

CRAWLER

6 replacement is the roller must be To accomplish this:

If bushing replacement is necessary the roller must be removed from the machine. To accomplish this:

the as described in the topic REPLACE-

1. Relieve the crawler belt tension as described in the topic CRAWLER BELT REPLACEMENT.

2. U sing the machine leveling jacks, raise the machine sufficiently to allow removal of the roller. Block the machine in the raised position. It may be necessary to jack the crawler belt away from the crawler frame and block in position to remove the extreme front or rear rollers.

3. Remove lubrication guards and lube lines if so equipped to gain access to the roller shaft.

sing the machine leveling jacks, raise the the roller. Block the machine in the raised posiIt may to crawler belt away from the crawler frame and block in the rollers. Remove so to access to the roller shaft.

4. Remove the cotter pin and T-bolt securing the lower roller shaft to the crawler frame.

4. Remove and the roller to

5. Support the lower roller with suitable blocking.

6. Remove the roller shaft.

5. Support lower roller Remove the

7. the blocking and lower the roller

7. Remove the blocking and lower the roller out of the crawler frame.

8. Inspect the roller bushing. Remove and'replace the bushing if necessary.

9. Inspect the lower roller shaft. Replace if worn.

8. the roller bushing. Remove and'rethe bushing necessary. the lower roller shaft. Replace if worn.

10. Inspect the roller thrust washers. Replace if necessary.

10. Inspect if

11. Inspect the crawler frame in the area of the lower roller. Repair shaft bore or thrust surfaces if necessary.

12. Lubricate the roller bushing, shaft and thrust washers.

13. Install thrust washers on roller.

crawler in lower roller. Repair shaft bore thrust faces if necessary. the bushing, and on

14. Install roller in crawler frame and block inline with the shaft bore.

15. Insert roller shaft.

14. with bore. roller shaft.

16. Install the T-bolt and cotter pin to secure roller shaft to crawler frame. Remove the roller blocking.

cotter to secure roller shaft to crawler frame. Remove the Install guards

17. Install lubrication guards and lube lines if so equipped.

18. Adjust belt tension described in the topic CRAWLER BELT ADJUSTMENT.

18. Adjust belt tension as described in the topic CRAWLER BELT ADJUSTMENT.

19. lower the machine to distribute the evenly in roller operation.

19. Remove blocking and lower machine. Propel the machine to distribute the grease evenly in the roller and check roller operation.

UPPER ROLLERS

Inspect the upper rollers for cracks and damage that can impair normal tracking of the crawler belts (figure 7).

Inspect upper for and damage can tracking crawler belts (figure 7).

FIGURE 6

1. CRAWLER FRAME 2. LOWER ROLLER 3. ROLLER BUSHING 4. THRUST WASHER

5. ROLLER SHAFT 6. SHAFT T -BOLT 7. CRAWLER BELT

FIGURE 7

5. CRAWLER BELT 6. BLOCKING 7. HYDRAULIC JACK

1. UPPER ROLLER

2. ROLLER SHAFT

3. SHAFT COTTER PIN

4. CRAWLER FRAME

2. LOWER ROLLER

3. ROLLER BUSHING THRUST WASHER

ROLLER SHAFT T -BOLT

7. CRAWLER BELT

FIGURE

1. UPPER 5. CRAWLER 6.

3. SHAFT HYDRAULIC JACK 4. FRAME

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