CAT Bucyrus 60R 61R Electrical Blast Hole Drill Mechanical Maintenance Manual BI005541 – PDF DOWNLOAD
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CAT Bucyrus 60R 61R Electrical Blast Hole Drill Mechanical Maintenance Manual BI005541 – PDF DOWNLOAD
Language : English
Pages : 512
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
CAT Bucyrus 60R 61R Electrical Blast Hole Drill Mechanical Maintenance Manual BI005541 – PDF DOWNLOAD
FOREWORD:
- The purpose of this manual is to provide information concerning the general maintenance of the
60/61-R rotary blast hole drill. - The 60/61-R consists of three major units, the lower works, the mainframe and the mast. Thelower
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 encloses 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 and indicates that injury to
personnel could occur if the proper procedures are not followed dunng 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
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 Bucyrus 60R 61R Electrical Blast Hole Drill Mechanical Maintenance Manual BI005541 – PDF DOWNLOAD
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 15
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 20
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 24
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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 , 34
Adjustment ” 34
Repair 35
Auxiliary Reel Brake , , 36
Adjustment 37
Repair , 37
Propel Brakes , 38
Adjustment 38
Repair 38
Hoist·Auxiliary Reel Clutch Lever 39
Adjustment 39
Repair 40
Hydraulic Pulldown Motor Clutch Lever 4:1
Adjustment 41
Repair 42
Hoist Limit Switch and Selsyn Indicator 43
Repair , ” 43
Diesel Engine 45
Replacement of Drive Bolts , ” 45
Belt Adjustment 46
Cable Reel , 46
Repair 46
Cable Reel Controls 50
Adjustment , 50
Section 4 MAST J Mast Structure 51
Repair 51
Mast Lock Latch , 52
Repair 52
Rotary Gearcase (Standard) 54
Adjustment 54
I& Repair 55
Rotary Gearcase (Super Heavy Duty) 57
Drive Shaft Adjustment 57B
Repair 57B
Rotary Motor (Standard Gearcase) 57E
Rotary Motor (Super Heavy Duty Gearcase) 57E
Rotary Coupling ‘ 57F
Repair 57F
Rotary Shock Sub 57F
Repair 58
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2
Rotary Guide Frame (Standard) , ‘” 5
Adjustment 6
Repair 6
Rotary Guide Frame (Special) 6
Adjustment , , , 6
Repair 6
Pulldown Chains 6
Adjustment 6
Repair 6
Pulldown Chain Equalizer 6
Repair 6
Tool Racks : 6
Repair : 6
Tool Wrenches , 7
Repair 7
Back Braces 7
Repair 7
Adjustment , 7
CHAPTER 2 – HYDRAULIC SYSTEM
Section 1 -SYSTEM OPERATION
Cylinder Circuit Hydraulic System 7
Pulldown Circuit Hydraulic System (Standard) 7
Pulldown Circuit Hydraulic System (Automated) 7~
Section 2 – GENERAL MAINTENANCE
Hydraulic System Cleanliness 8
Oil Requirements k’ ••••••••••••••••••••••••••••••••••••••••••••••••••••• 8
Oil and Filter Changes 8
Weekly Maintenance Checks 8:
Oil Reservoir Repairs 8~
Unloader Valve Adjustment 8~
Pressure Regulating (Relief) Valve Adjustment 8~
Chain Equalizer Valve Adjustment 8:
Servo Valve 8~
Section 3 -COMPONENT MAINTENANCE
Hydraulic Pump Overhaul 8E
Disassembly 8E
Cleaning 8E
Inspection 86
Reassembly 86
Test Procedure ” 88
Main Valve Banks 88
General 88
Disassembly 88
Cleaning, Inspection and Repair 90
Assembly 90
Hydraulic Pulldown Motor 90
Disassembly 90
Cleaning, Inspection and Repair ~ 92
Reassembly 92
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Disassembly of Chain Equalizer Valve Relief Valve Cartridge 92
Hydraulic Oil Cooler 93
Weekly Maintenance Check ” 93
1000 Hour Maintenance Check 93
Yearly Maintenance Check 93
CHAPTER 3 – AIR SYSTEMS
J
Section 1· SYSTEMS OPERATION
General 95
Main Air System 95
Auxiliary Air System 95
Safety 97
Section 2 – GENERAL MAINTENAJ “J’CE
Main Air System 99
General ‘ 99
Intake Air Filter – Box Type 99
Intake Air Filter – Tubular Type 99
Filter Replacement 100
Compressor Lubricator (Vane Compressor Only) 100
Feed Rate 100
Viscosity Grade 101
Lubricator Daily Maintenance Check 101
Lubricator Weekly Maintenance Check 101
Lubricator Service 101
Lubricator Priming 101
Compressor Radiator 102
Safety Valve Settings • ” 102
Drill Pressure 102
Auxiliary Air System 102
Auxiliary Air Compressor 102
Miscellaneous Components 103
Unloader Check Valve Service 103
Tanner De-icer (optional) 103
Air Tanks _ , 104
Air Tank Valves 104
Pressure Switch 104
Filter 104
Anti-Freezer – 104
Maintenance Procedure for Air Dryer 104
Desiccant Canister Removal 105
Purge Valve Removal : 106
Section 3 AUXILIARY AIR COMPRESSOR (KELLOGG-AMERICAN)
Disassembly of Pump 109
Fitting and Reassembling 110
Section 4 – MAIN AIR COMPRESSOR
Rotary Vane Compressor (Allis-Chalmers) 113
1000 Hour Maintenance Check 113
4000 Hour Maintenance check 114
Blade Protection in Idle Units 117
Rotor Alignment for Redoweling 118
Rotor Field Redoweling 118
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Rotary Screw Compressor (Allis-Chalmers) 120
Description 120
Coupling Alignment 120
Start-Up Procedure 121
Controls and Instruments 122
Lubrication System 127
Air Filters 133
Maintenance Schedule 135
CHAPTER 4 – DUST CONTROL
Section 1- GENERAL MAINTENANCE
Drilling Platforms and Dust Curtains 141
Filter Air-Bag System (Amerpulse®) 141
Daily Maintenance Checks 141
Monthly Maintenance Checks 141
Six Month Maintenance Checks 142
Water Injection (using water pump) 142
Water Injection (pressurized) 142
Cold Weather Protection System 143
Section 2 – MAINTENANCE OF AMERPULSE®
Operating Principles 145
Filter Tube Installation 145
Printed Circuit Timer Test ” 146
Solenoid Valve Test 147
Pulse Recommendations 147
Hopper Vibrator 147
——‘
CHAPTER 5 – LUBRICATION
Section 1 LUBRICATION PROCEDURES
General 149
Lubricant Cleanliness 149
Automatic System Lubrication Points 149
Lubricant Benchmarks 150
Lubrication Charts
Gearcase and Reservoir Capacities 150
Lower Works 151
Mainframe (Part 1) 152
Mainframe (Part 2) 153
Mast (Part 1) 154
Mast (Part 2) 155
Mast (Part 3) 156
Section 2· LINCOLN AUTOMATIC SYSTEM
Troubleshooting Systems 157
Air Locks 157
Dirty Supply Lines 157
All Injectors Do Not Function Properly , 157
After Venting, the Indicator Stems on the Injectors
Do Not Return to Their Normal Position 157
Failure of Pump to Build Up Pressure 158
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Sluggish Pump Operation 158
Slow Pressure Rise 158
Assembly of Tubing Compression Fittings 158
Principle of Operation – Pump Air Motor 158
Service of Lower Pumping Unit 160
Lubrication 161
Installation, Operating, and Maintenance Instructions 161
Section 3 -TRABON AUTOMATIC SYSTEM
Locating Blockage in System 165
Terminology ” 165
Procedure 165
Torque Information in Foot Pounds 168
Section 4 – VANE TYPE MAIN COMPRESSOR LUBRICATOR OR BIT LUBRICATION
Operation and Adjustment 169
To Start Lubricator 169
To Adjust Lubricator 169
Sight Feed Unit 169
Purging Oil From Pumping Unit 169
Care of Lubricator 170
CHAPTER 6 – TROUBLESHOOTING
General 171
Drilling 172
Rotary Drive Unit 174
Hoist-Propel Transmission 174
Mast 175
Main Air Compressor (vane type) 175
Main Air Compressor (screw type) 178
Auxiliary Air Compressor 181
Hydraulic System 182
Hydraulic Oil Cooler 183
Hydraulic Cylinder 183
Hydraulic Pump 184
Hydraulic Pulldown Motor 186
Pressure Regulating and Pulldown Pressure Relief Valves 187
Hydraulic Chain Equalizer Pump 188
Control Valves 188
Unloader Valves 189
Servo Valve 190
Amerpuls~ 191
——-APPENDICES
Appendix Al GEAR INSPECTION 1A
4~
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Appendix A2 – BOLT TORQUING
Torque Wrench Method
Turn·Of·The-~ut Method _ _ ” 2(
Appendix A3· PINION AND COUPUNG D;STALLATION
Removal For Motor Shaft 3j
Mounting Pinion or Coupling Shaft 3j
Appendix A4 – LUBE BENCHMARKS
Multipurpose Type Grease (MPG) _ ” 5P
Air Compressor (vane type) Lubricant (ACVL) 6P
Air Compressor (piston type) Lubricant (ACPL) 7P
Chain Drive Lubricant (CDL) _ 8P
Drill Pipe Thread Lubricant (DPTL) 9P
Multipurpose Oil (MPO) , 10P
Open Gear Lubricant (OGL) lOP
Regular Type Gear Lubricant (RGU , ” 12A
Running Wire Rope Lubricant (RWRL) 16A
Hydraulic Oil for Mining Machinery (HYDO I 17A
Appendix A5 -RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRI:\,CIPAI
STRUCTURES ON BLAST HOLE DRll LS
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 _ 24A
Weld Inspection – 24A
Repair of Broken Parts 24A
Methods of Repair of Cracks – 24A
Appendix A6· PREVENTIVE MAINTENA ‘JCE CHECKUSTS
Level I Inspection 25A
Level II Inspection 30A
Level III Inspection 32A
Appendix A7 – SPECLAJ 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 (Standard) ~ 36A
Rotary Gearcase Shafts (Super Heavy Duty) 37A
Rotary Unit Shipper Shaft 38A
Drive Tumbler Shaft 38A
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- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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