Cat 45-R Blast Hole Drill Technical Manual – CAT Rotary Track Drills – PDF DOWNLOAD (BI005448)
DESCRIPTION:
Cat 45-R Blast Hole Drill Technical Manual – CAT Rotary Track Drills – PDF DOWNLOAD (BI005448)
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 CA UTI ON’s and W ARNIN 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.
TABLE OF CONTENTS:
Cat 45-R Blast Hole Drill Technical Manual – CAT Rotary Track Drills – PDF DOWNLOAD (BI005448)
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
BI005448
Pulldown 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 Pull down Motor Clutch Lever 42
Adjustment 42
Repair 43
Section 4 -MAST
Mast 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
Rotary 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
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Unloader Tool Racks 65
Repair 65
Tool Wrenches 67
Repair 68
Back Braces 68
Repair 68
Adjustment 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
Un loader 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
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
CHAPTER 3 – AIR SYSTEMS
Section 1- SYSTEMS OPERATION
General 87
Main Air System 87
Auxiliary Air System 87
Safety 87
© BUCYRUS-ERIE COMPANY, 1983
BI005448
” 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 Radiator 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
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 , ” ” ‘109
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
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CHAPTER 4 – DUST CONTROL
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
Operating Principles 137
Filter Tube Installation 137
, ” , , Solenoid Valve Test 139
Pulse Recommendations 139
Hopper Vibrator 139
CHAPTER 5 – LUBRICATION
Section 1- LUBRICATION PROCEDURES
General 141
Service of Lower Pumping Unit , , , , , ” ” , 152
Lubrication 153
Installation, Operating, and Maintenance Instructions , 153
Section 1 – GENERAL MAINTENANCE
Water Injection (using water pump) 134
Water Injection (pressurized) 134
Cold Printed Circuit Timer Test 137
Lubricant Cleanliness 141
Automatic System Lubrication Points 141
Mainframe (Part 1) 144
Mainframe (Part 2) 145
Mast (Part 1) 146
Mast (Part 2) 147
LINCOLN AUTOMATIC SYSTEM
Troubleshooting Systems 149
Dirty Supply Lines 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
© BUCYRUS-ERIE COMPANY, 1983
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Section 3 -TRABON AUTOMATIC SYSTEM
Locating Blockage in System 157
Terminology Information in Foot Pounds ~ 160
CHAPTER 6 – TROUBLESHOOTING
General ” 164
Rotary Drive Unit 166
Hoist-Propel Transmission 166
Hydraulic Pump ” 176
, Amerpulse® ” 182
Appendix Al -GEAR INSPECTION 1A
Appendix A2 – BOLT TORQUING
Bolt Torque Values for Static Joints Bulletin 6-82-1
Appendix A4 – LUBE BENCHMARKS
Multipurpose Type Grease (MPG) Lubricant (ACVL) ” 6A
Procedure 157
Torque 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
Section 1 -TROUBLESHOOTING
163
Drilling 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 Hydraulic Pulldown Motor 178
Pressure Regulating and Pulldown Pressure Relief Valves 179
Hydraulic Chain Equalizer Pump 180
Control Valves 180
Unloader Valves 181
APPENDICES
Appendix A3 -PINION AND COUPLING INSTALLATION
Removal For Motor Shaft 3A
Mounting Pinion or Coupling Shaft 3A
5A
Air Compressor (vane type) BI005448
BUCYRUS-ERIE COMPANY, 1983
Air Compressor (piston type) Lubricant (ACPL) 7 A
Chain Drive Lubricant (CDL) 8A
Drill Pipe Thread Lubricant (DPTL) 9A
Multipurpose Oil (MPO) lOA
Open Gear Lubricant (OGL) lOA
Regular Type Gear Lubricant (RGL) 12A
Running Wire Rope Lubricant (RWRL) 16A
Hydraulic Oil for Mining Machinery (HYDO) 17 A
Appendix A5 -RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRINCIPAL
STRUCTURES ON BLAST 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-Pulldown 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
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