Technical Manual
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Publication No. 45R-MMM
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 the hoist-propel transmission and the machinery house. The machinery house encloses the majority of the mechanical ment 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. Itis 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 eachmethod. 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 orits equipment that are not detailed in this manual.
CHAPTER!
SECTION 1 - MAINTENANCE PROCEDURE
GENERAL
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 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 ofthe 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 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?
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?
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.
h 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.
CHAPTERl
SECTION 2 - LOWER WORKS
eRA WLER 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"-6" inches at the center points between the upper rollers (figure 2).
Adjustment of the 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).
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 craw ler frame.
4. Position suitable hydraulic jacks behind each of the bearing blocks.
6. Remove several shims from in front of the bearing blocks.
s. Using 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 pms.
10. Remove any equipment securing the belt against movement.
II. Readjust belt tension as described in the CRA WLER BELT ADJUSTMENT topic of this manual.
BELT REPLACEMENT (Figure 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.
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. Partthe belt at a point midway between the upper rollers by removing the link pins.
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. 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.
Assemble the new belt and lay it flat on the ground near the crawler frame.
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.
Remove the blocking and slowly lower the machine until the crawler rollers and tumblers are resting on the belt.
Using a suitable lifting device, lift the ends of the belt into a position to insert the link pins.
Insert the link pins and cotter pins to complete the belt.
Readjust the belt tension as described in the topic CRAWLER BELT ADJUSTMENT.
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 of the roller bushing by lifting and then lowering the roller. Replace the 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.
Every six months remove the weight of the crawler belt from the rollers and check the rollers for bore elongation and wear. Replace the rollers if badly worn.
REPAIR
The upper rollers are not subjected to load conditions other than the weight and deflection of the crawler belts. The most common problem encountered is bore wear.
If replacement is necessary, the upper roller must be removed from the machine. To remove the roller:
1. Relieve crawler belt tension as described in the topic CRAWLER BELT ADJUSTMENT.
2. Raise the belt with a suitable lifting device until it clears the upper roller. Block belt in raised position.
3. Remove lube line if so equipped. Remove the cotter pin securing the roller shaft to the crawler frame.
4. Support the roller and remove the roller shaft.
5. Remove the roller from the crawler frame.
6. Inspect the roller bore and thrust surfaces. Replace roller if necessary.
7. Inspect roller support on crawler frame. Repair if necessary. .
8. Inspect roller shaft. Replace if worn.
9. Lubricate roller bore and shaft.
10. Insert roller into crawler frame.
11. Insert roller shaft. Install cotter pin. Install lube line if so equipped.
12. Remove blocking holding the belt.
13. Adjust belt tension as described in the topic CRAWLER BELT ADJUSTMENT.
14. Propel the machine to distribute the grease evenly and check operation of roller.
DRIVE TUMBLERS
Inspect the drive tumblers for cracked and broken lugs and other defects that can impair normal tumbler function and belt tracking (figure 8). Check the tumbler shaft retainer bolts for tightness. Every six months, remove the tumbler shaft
retainer and check the tumbler drive shaft bushings for wear. Replace bushings if badly worn.
REPAIR
Repair of the drive tumbler is limited to repair welding of the lugs or roller area or replacemen t of the entire unit. Refer to the welding instructions in the APPENDIX for exact weld repair procedures
To replace the drive tumbler:
1. Relieve the crawler belt tension and separate the crawler belt as detailed in the CRAWLER BELT REPLACEMENT topic of this manual. Separation of the crawler belt should take place near the drive tumbler and the links laid back out of the way.
2. Using the machine leveling jacks, raise the machine sufficiently to allow the drive tumbler to clear the lugs on the crawler belt. Block the machine in the raised position.
3. Relieve the propel drive chain tension as described in PROPEL DRIVE CHAIN ADJUSTMENT and separate the propel drive chain. Remove the chain from the drive sprocket.
4. Remove the retainer bolts and retainers from each end of the drive shaft.
5. Remove the drive sprocket from the inboard end of the drive shaft.
encountered is bushing wear. However, it is possi-
13. Install the bearing block adjustment bolts. ble for the tumbler to develop cracks. When cracks Do not tighten the nuts at this time.
do occur, they can be repaired by gouging out
14. Reassemble the crawler belt. metal on both sides of the crack, and welding the crack. Follow welding instructions in appendix.
15. Adjust the crawler belt tension as per topic If bushing replacement is needed, the tumbler CRAWLER BELT ADJUSTMENT. Tighten must be removed from the machine. To accom- the bearing block adjustment bolts. plish this:
16. Replace the shim guards and lube lines if so
l. Position the machine so that the take-up equipped. tumbler to be removed is over a slight depres-
17. Propel the machine to distribute the grease sion (about 6" deep). This depth will be evenly in the tumbler bushing and check enough to relieve the weight of the machine operation of tumbler. from the tumbler.
2. Relieve crawler belt tension and separate the
CRAWLER FRAMES
crawler belt as described in the topic Inspect the crawler frames for cracks or damage CRAWLER BELT REPLACEMENT. Sepa- (figure 10). Pay particular attention to the axle ration ofthe belt should take place at a point attachment points and the bottom flange plate. near the. take-up tumbler, and the links laid
Any cracks, wear or damage should be repaired back out of the way. immediately, following the repair welding proce-
3. Remove the shim guards and lube lines if so dures listed in the APPENDIX of this manual. equipped.
4. Remove the bearing block adjustment bolts
REPAIR
Repair of the crawler frames may be accomplished and upper halves ofthe bearing blocks. Mark while the crawler frames are attached to the drill the upper halves ofthe bearing blocks so that or the crawler frames may be removed to faciliate
they will be reinstalled in the same position. repair.
5. Using a suitable lifting device, remove the
To remove the crawler frames from the machine take-up tumbler and shaft. Remove the shaft proceed as follows: from the tumbler.
1. Separate the propel drive chain. Remove the
6. Inspect the tumbler bushings and thrust sur- chain from the tumbler drive sprocket. faces. Remove and replace the bushings if necessary.
2. Disconnect all lubrication lines connecting
7. The thrust surfaces of the tumbler may be crawler frame to mainframe, if so equipped. rebuilt to original dimensions. Follow the
3. Using the machine leveling jacks, raise the welding procedures listed in the APPENDIX machine sufficiently to allow blocking to be of this manual. placed under the crawler belts and extending Inspect the tumbler shaft and replace if 6 to 8 feet from the crawler frame. Blocking
8. material should be selected to facilitate the necessary. sliding of the crawler frame away from the
9. Inspect and clean the bearing block halves. machine. Replace if worn.
4. Slowly lower the machine until there is no
10. Inspect the crawler frame in the areas where weight on the rear axle or equalizer axle. the bearing block rests. Rebuild and grind Securely block the machine in this position. flat if worn.
5. From this point either one or both crawler
II. Lubricate the tumbler bore and shaft and frames may be removed from the machine. install the shaft in the tumbler. Using a suit- NOTE: Steps 6 through 16 describe the able lifting device position the tumbler and procedure for removing and reinstalling one shaft in the crawler frame and lower halves crawler frame. If both frames are to be of the bearing blocks. removed, repeat steps 6 through 16 for the
12. Install the bearing block upper halves. other crawler frame.
17. Raise the machine with the leveling jacks just enough to remove the blocking, then lower the machine.
18. Propel the machine to check the operation of the propel drive chains and crawler components.
AXLES
The crawler frames are attached to the machine by two axles. The front axle (equalizer axle) (figure 11) allows the front of the crawlers to pivot, equal· izing the load of the machine between the two crawlers. Each end of the axle is pinned to the crawler frames while the middle of the axle is pinned to the bottom of the drill mainframe.
The rear axle (figure 12) is the pivot axle in that as the front of the crawlers move up and down to equalize the loads, the rear of the crawler pivots about the rear axle. This axle is solidly attached to both sides of the mainframe and does not move during operation. The rear axle is moved forward or backward to adjust the propel drive chains. Inspect the axles and the attachment points frequently for loose bolts or hardware. Inspect the axles for cracks or damage. Repair or replace the axles if worn or damaged. Inspect the pivot pins and retainers for wel'.lr or damage and replace as necessary.
9
8. SHIM
9. MAINFRAME
take place near the tumbler drive sprocket. Note that some brands of chain require that the "master" link be removed to separate the chains.
4. Repair or replace chain as needed.
5. Reinstall the drive chain on the sprockets. Careful use of propel power is allowable to facilitate installation of the chain on the small drive sprocket.
6. Join the drive chain by inserting the link pin. Secure the link pin with the appropriate retainer.
7. Adjust the drive chains per CHAIN ADJUSTMENT topic.
ADJUSTMENT
Adjustment of the propel final drive chains is accomplished by moving the entire lower works forward or rearward in relationship to the drill mainframe. To tighten the chains the lower works is jacked rearward and to loosen the chains it is
jacked forward. The chains are adjusted correctly when there is between 3"-5" of slack in one side of the chain when the opposite side is tight.
To adjust the propel drive chains:
1. Loosen the take-up bearing U-bolt jam nuts and full nuts. Loosen the nuts only enough to allow the axle to slide under the pressure of the hydraulic jacks.
2. Using the machine leveling jacks, raise the machine so that the crawlers are free of the ground. Block the machine in the raised position.
3. Remove the shim retainer pins from the takeup bearings.
4. Install suitable hydraulic jacks in the notched portion· of the shims. To tighten the chains place the jacks in front of the axle. To loosen the chains place the jacks behind the axle.
5. Remove the shims on the side of the take-up bearings opposite of where the jacks were installed.
CHAPTERl
SECTION 3 - MAINFRAME
MAINFRAME AND MAST SUPPORT
The 45- R drill mainframe consists basically of two I-beams tied together with bracing and covered on the top surface with deck plates. The mast support consists of wide flange beams which are welded to the drill mainframe and tied together with formed plates.
Inspect the drill mainframe and mast support for wear, damage or cracks. Pay particular attention to the following critical areas:
L Cross bracing which ties the bottom flanges of the I-beams together.
2. Cross bracing and deck plates which tie the top flanges of the I-beams together.
3. Mast lock pin attachment areas.
4. Leveling jack attachment areas.
5. Areas where the mast support is welded to the mainframe.
6. Mast hinge pin areas on the mast support.
7. Mast hoist cylinder attachment lugs and the immediate area surrounding these lugs on the mainframe.
REPAIR
Cracking, wear or damage to the critical areas listed above required immediate repair. The urgency of repair to other areas of the mainframe is dictated by the area in which the repair must be done and the severity of the damage. Minor damage may not require immediate attention but all damage to the mainframe or mast support should be repaired at the first available opportunity.
Repair to the mainframe and mast support is limited to repair welding. Follow the recommended procedures detailed in the APPENDIX to complete welding repairs. If damage is severe or unusual circumstances arise, contact the Bucyrus-Erie Service Department for specific recommendations.
LEVELING JACKS
Inspect the leveling jacks for structural damage, proper lubricant coating and proper operation (figure 14). Verify that all bolts are tight and all pins are in place.
Check the jack pads for cracks or damage. Clean excess material from the jack pads. Check the jack spuds for wear or damage. Verify that the spuds are coated with grease.
5-_"","1
6 __
unit and to remove any air pockets created during the repair procedures. The jack should be extended and retracted to the maximum position to accomplish this.
MACHINERY HOUSE
Frequently inspect all house panels and structural members for cracking. Include a close examination of all roof structures and bracing. Always restore defective structural members to their original state by repair welding.
Periodically inspect the hinges and latches on all doors and windows to insure they will remain closed during machine operation. Verify the sealing of all doors and windows to prevent the en trance of dust. Search thoroughly for all loose or missing bolts. 'rhe absence of these fasteners can result in excessive vibration and wear of house components.
Inspect the condition ofthe paint on both the interior and exterior surfaces of the house. Prepare and paint any areas where the paint has been damaged or any areas where repairs have been made.
REPAIR
Repair of the machinery house is usually limited to repair of individual structures within the house. Repair welding should follow the guidelines detailed in the APPENDIX. Any repair procedure should be undertaken with the object being to preven t the en trance of dust, dirt, or moisture in to the house. All joints in the house structure should be adequately sealed and openings in the machinery house should be kept to a minimum.
The machinery house roofis removable, aswell as two cross members over the main air compressor. Verify that the cross members are securely fastened. Verify that the roof is sealed properly and that the clamps are secured. Verify that the rain cap over the front edge of the roof is secured and sealed.
HOUSE VENTILATION FAN AND FILTER
The machinery house is equipped with a ventilation fan and inertial filter which provides clean ventilation air to the main air compressor and machinery house. The machinery house is pressurized slightly above atmospheric pressure by the fan. This serves to keep dust and moisture from entering the machinery house. The ventilation fan should be operating any time the machine
is being operated. Keep all machinery house doors closed at all times to prevent the entrance of dust. Inspection of the ventilation fan itself is not required except as necessary to repair some malfunction.
The inertial filter cleans the air entering the machinery house. This filter is self-cleaning and does not require routine service typical of other filters. Proper operation of the filter, however, is dependent upon proper air flow. Restriction ofthe intake by leaves, rags and paper will lessen the effectiveness ofthe filter and ventilation fan. A light coating of dust on the blades of the filter is normal and will not impair the efficiency of the filter. The filter is automatically cleaned by reversing the air flow every time the fan motor is started. This cleaning, however, cannot remove material which has accumulated on the blade surfaces. To remove this material it is necessary to wire brush the blades while the fan is running in reverse or remove the filter cell and steam clean the blades.
WALKWAYS AND LADDERS
Inspect all handrails, walkways, platforms, stairs and ladders on the machine daily. Verify that all structural members are in good repair and that all fasteners and welds are intact. Repair or replace components immediately to insure the integrity of the structures and ensure compliance with safety regulations.
Keep all walkways, stairways and ladders clear of materials which could present slipping or tripping hazards. Keep walkways clear of tools, supplies or other obstructions. Clean up all grease or oil spills immediately,
OPERATOR'S CAB
Inspect the operator's cab daily for or structural damage to all side, roof and floor panels. Check the doors and windows for proper operation and correct sealing. Check the area behind the operator's console for air, water or oil leaks. Repair any leaks immediately. Keep the cab clear of all oil,grease or water spills to help prevent slipping.
OPERATOR'S SEAT
The individual operator may adjust the operator's seat as desired with respect to height, tilt and travel. Periodically oil all bearings and pivot points to maintain smooth movement.
• 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.