Bucyrus International, Inc.

39HR Blast Hole Drill

Section 7
Compressed Air System
Always refer to the safety information in Section 1 of this manual before
starting any maintenance procedure on this machine.

Table of Contents

AIR COMPRESSOR ASSEMBLY .................................................................................................. 4

Air Compressor - Left Side .......................................................................................................... 4
View A - Right Side ..................................................................................................................... 5
View B - Separator Controls ........................................................................................................ 6
COMPRESSOR VARIABLE VOLUME OPTION ..................................................................... 7
Variable Volume Controls ........................................................................................................... 7
COMPRESSOR AIR INTAKE FILTERS ................................................................................... 8
Air Cleaner Assemblies and Intake Manifold ............................................................................... 8
COMPRESSOR OIL DRAIN VALVE ........................................................................................ 9
SEPARATOR MAINTENANCE ................................................................................................ 9
Separator Tank Internal Filters ................................................................................................... 10
COMPRESSOR AIR END ..................................................................................................... 11
Compressor Air End Assembly .................................................................................................. 11

SCHEMATIC, COMPRESSED AIR ..................................................................................... (insert)

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Manual No. 10660 7-2 Nov 2008

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39HR Blast Hole Drill

Section 7
Compressed Air System

The main air system supplies compressed air for bailing the hole during drilling. The air also cleans
and cools the bearings in the bit. The air is compressed by a rotary oil flooded screw air compressor.
Inlet air passes through a filter before entering the compressor.

Inside the air end the air stream will pass through a poppet valve used to control the amount of air
in the compressor. Oil is then injected into the air stream to lubricate, cool and seal the screws of
the air end. The compressed air/oil mixture leaves the air end and enters the separator tank. The
separator tank removes the oil from the air stream. The separator uses swirling action to remove
the oil from the air. The air is then passed through a butterfly valve into the mast air pipe.

When the main air valve is activated, a butterfly valve in the mast air pipe is opened and the air
flows through the main air piping to the rotary head. A passage in the rotary shaft allows air to flow
into the drill pipe, through the bit and out of the hole, carrying out the cuttings.

When the compressor is unloaded by the operator switching into vent mode, the poppet valve at
the inlet of the compressor closes, the main air valve closes in the discharge pipe, and the blowdown
valve opens allowing the air in the tank to return to atmospheric pressure.

The general maintenance required for the main air system consists mainly of inspection of the
components of the system to see that they are working properly and that all liquids are at their
proper levels.

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39HR Blast Hole Drill

AIR COMPRESSOR ASSEMBLY

The air compressor assembly is composed of the air end, separator tank and associated piping,
valves, gauges and filters. The compressor is located on the left side of the machine, at the rear of
the power module.

Air Compressor - Left Side

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 Bucyrus International, Inc.

39HR Blast Hole Drill

View A - Right Side

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39HR Blast Hole Drill

View B - Separator Controls

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 Bucyrus International, Inc.

39HR Blast Hole Drill

COMPRESSOR VARIABLE VOLUME OPTION

This machine’s compressor assembly is equipped with a variable volume option. The system
includes an additional control manifold, hoses, junction box and wiring which are all located on the
left side of the compressor assembly.

Variable Volume Controls

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39HR Blast Hole Drill

COMPRESSOR AIR INTAKE FILTERS

CAUTION: Take care to not allow dust, dirt or any foreign objects to fall into the
compressor inlet during filter servicing.

This machine uses three air filter assemblies. They are located above the air cleaner manifold
which is bolted to the air compressor inlet. To replace a filter element, remove the top cover, replace
the element and reinstall the cover. New sealing washers should be used when servicing the air
cleaner.

Should the air intake manifold require removal, remove the 12 hex head capscrews that fasten the
intake manifold to the air compressor inlet, then lift the intake assembly off the compressor intake.
Remove and replace the mounting gasket if required. Reinstallation is the opposite of removal.

An air filter indicator is located at the base of the intake manifold. Flow through the system will draw
the indicator in toward the component during operation. If airflow is indicated while the system is
off, push the reset pushbutton to restore the indicator.

Each of the three air cleaners located on top of the manifold consist of 1) a filter precleaner, and 2)
the air cleaner. The precleaner filter should be inspected frequently and cleaned whenever necessary.
The air cleaner medium should also be inspected at regular intervals (at least every two months),
or more often as conditions warrant. If dirty, the medium can be cleaned in a soapy water solution.
Allow the medium to dry completely before reinstalling it. The Primary Air Cleaner Medium should
be replaced annually, or whenever a tear, hole or rupture is found during inspection.

Air Cleaner Assemblies and Intake Manifold

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39HR Blast Hole Drill

COMPRESSOR OIL DRAIN VALVE

A drain valve is located beneath the power module base, immediately below the separator tank.
Use this valve to drain oil from the tank. Also located here is a quick fill port.

SEPARATOR MAINTENANCE

The air compressor separator tank contains 4 air filter cartridges. These must be changed at 1000
hours or anytime more than 10 PSI pressure differential exists across the filters, or if the compressor
starts to bypass oil. To replace the separator filter cartridges:

1. Shut down the machine. Ensure that the electric motor and compressor is powered down.
Relieve any residual pressure in the main air line and the separator tank.

2. Loosen the hex nuts that attach the separator cover to the tank. Loosen each nut enough to
allow the attaching bolt to be pulled away from the tank and lowered.

3. Use the installed hydraulic jack at the lower, front of the separator tank to raise the separator
cover enough to clear the filter cartridges.

4. Once lifted, rotate the cover out of the way.

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39HR Blast Hole Drill

Separator Tank Internal Filters

5. Remove the 3 hex nuts and the filter retainer which covers one of the filter cartridges.

6. Pull the filter cartridge out of the separator tank. Repeat for the remaining 3 cartridges.

Inspect all parts. Repair or replace as required.

Reassembly is the opposite of disassembly.

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39HR Blast Hole Drill

COMPRESSOR AIR END

Compressor Air End Assembly

When replacing the filter elements, use the following procedure:

1. Shut down the compressor and relieve all pressure.

2. Place a large oil pan under drain

3. Remove drain plug and drain oil. Replace and tighten plug.

4. Remove filter elements. Dispose of used elements.

5. Apply a small amount of clean oil to the filter element seals.

6. Inspect the new filter elements and tighten per manufacturer’s specification.

7. Fill compressor with new oil per manufacturer’s specification.

NOTE: For Compressor oil requirements and procedures, refer to Section 3 - LUBRICATION
in this manual.

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39HR Blast Hole Drill

Manual No. 10660 7 - 12 Nov 2008