Bucyrus 60/61R Electric Blast Hole Drill Mechanical Maintenance Manual – CAT Rotary Track Drill 60/61R – PDF DOWNLOAD
DESCRIPTION:
Bucyrus 60/61R Electric Blast Hole Drill Mechanical Maintenance Manual – CAT Rotary Track Drill 60/61R – 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.
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 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 A 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 proRer 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 UTION’s and WARNING’s are not all-inclusive. 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:
Bucyrus 60/61R Electric Blast Hole Drill Mechanical Maintenance Manual – CAT Rotary Track Drill 60/61R – PDF DOWNLOAD
COVER PAGE................................................................................................ 1
FOREWORD.................................................................................................. 2
TABLE OF CONTENTS......................................................................................... 3
MECHANICAL MAINTENANCE.................................................................................... 9
MAINTENANCE PROCEDURE................................................................................. 9
GENERAL........................................................................................... 9
MAINTENANCE SCHEDULES AND REPORTS................................................................. 9
SAFETY............................................................................................ 10
GENERAL....................................................................................... 10
IN-OPERATION MAINTENANCE...................................................................... 10
PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK................................................ 10
LOWER WORKS........................................................................................... 12
CRAWLER BELTS..................................................................................... 12
ADJUSTMENT.................................................................................... 12
LINK REPLACEMENT.............................................................................. 13
BELT REPLACEMENT.............................................................................. 14
LOWER ROLLERS..................................................................................... 14
REPAIR........................................................................................ 14
UPPER ROLLERS..................................................................................... 15
REPAIR........................................................................................ 16
DRIVE TUMBLERS.................................................................................... 16
REPAIR........................................................................................ 16
TAKE-UP TUMBLERS.................................................................................. 17
REPAIR........................................................................................ 17
CRAWLER FRAMES.................................................................................... 18
REPAIR........................................................................................ 18
AXLES............................................................................................. 20
REPAIR........................................................................................ 21
PROPEL FINAL-DRIVE CHAINS......................................................................... 21
REPAIR........................................................................................ 21
ADJUSTMENT.................................................................................... 22
MAINFRAME............................................................................................. 24
MAINFRAME AND MAST SUPPORT........................................................................ 24
REPAIR........................................................................................ 24
LEVELING JACKS.................................................................................... 24
REPAIR........................................................................................ 25
MACHINERY HOUSE................................................................................... 26
REPAIR........................................................................................ 26
HOUSE VENTILATION FAN AND FILTER.................................................................. 26
WALKWAYS AND LADDERS.............................................................................. 26
OPERATOR'S CAB.................................................................................... 26
OPERATOR'S SEAT............................................................................... 27
OPERATOR'S CONTROLS........................................................................... 27
VENTILATION UNIT.............................................................................. 27
HOIST-PROPEL GEARCASE............................................................................. 27
REPAIR........................................................................................ 27
REMOVAL AND INSTALLATION OF GEARCASE.......................................................... 28
GEARCASE SUSPENSION........................................................................... 29
HOIST-PROPEL GEARCASE DISASSEMBLY AND ASSEMBLY................................................ 30
HOIST SHAFT................................................................................... 31
SECOND INTERMEDIATE SHAFT..................................................................... 32
FIRST INTERMEDIATE SHAFT...................................................................... 33
IDLER SHAFT....................................................................................... 33
PROPEL SHAFT...................................................................................... 34
PROPEL CLUTCHES................................................................................... 35
REPAIR........................................................................................ 35
HYDRAULIC MOTOR SHAFT............................................................................. 36
ELECTRIC HOIST-PROPEL MOTOR....................................................................... 37
REPAIR........................................................................................ 37
PROPEL MACHINERY.................................................................................. 38
REAPAIR....................................................................................... 38
FIRST INTERMEDIATE SHAFT...................................................................... 38
SECOND INTERMEDIATE SHAFT..................................................................... 39
PROPEL CHAIN ADJUSTMENT....................................................................... 40
HOIST BRAKE....................................................................................... 41
ADJUSTMENT.................................................................................... 41
REPAIR........................................................................................ 42
AUXILIARY REEL BRAKE.............................................................................. 43
ADJUSTMENT.................................................................................... 44
REPAIR........................................................................................ 44
PROPEL BRAKES..................................................................................... 45
ADJUSTMENT.................................................................................... 45
REPAIR........................................................................................ 45
HOIST -AUXILIARY REEL CLUTCH LEVER................................................................ 46
ADJUSTMENT.................................................................................... 46
REPAIR........................................................................................ 47
HYDRAULIC PULLDOWN MOTOR CLUTCH LEVER............................................................. 48
ADJUSTMENT.................................................................................... 48
REPAIR........................................................................................ 49
HOIST LIMIT SWITCH AND SELSYN INDICATOR........................................................... 50
REPAIR........................................................................................ 50
DIESEL ENGINE..................................................................................... 52
REPLACEMENT OF DRIVE BELTS.................................................................... 52
BELT ADJUSTMENT............................................................................... 53
CABLE REEL........................................................................................ 53
REPAIR........................................................................................ 53
CABLE REEL CONTROLS........................................................................... 57
ADJUSTMENT.................................................................................... 57
MAST.................................................................................................. 58
MAST STRUCTURE.................................................................................... 58
REPAIR........................................................................................ 58
MAST LOCK LATCH................................................................................... 59
REPAIR........................................................................................ 59
ROTARY GEARCASE (STANDARD)........................................................................ 61
ADJUSTMENT.................................................................................... 61
REPAIR........................................................................................ 62
ROTARY GEARCASE (SUPER HEAVY DUTY)................................................................ 64
DRIVE SHAFT ADJUSTMENT........................................................................ 66
REPAIR........................................................................................ 66
ROTARY MOTOR (STANDARD GEARCASE).................................................................. 69
ROTARY MOTOR (SUPER HEAVY DUTY GEARCASE).......................................................... 69
ROTARY COUPLING................................................................................... 70
REPAIR........................................................................................ 70
ROTARY SHOCK SUB.................................................................................. 70
REPAIR........................................................................................ 71
ROTARY GUIDE FRAME (STANDARD)..................................................................... 72
ADJUSTMENT.................................................................................... 73
REPAIR........................................................................................ 74
ROTARY GUIDE FRAME (SPECIAL)...................................................................... 76
ADJUSTMENT.................................................................................... 76
REPAIR........................................................................................ 79
PULLDOWN CHAINS................................................................................... 82
ADJUSTMENT.................................................................................... 82
REPAIR........................................................................................ 82
PULLDOWN CHAIN EQUALIZER.......................................................................... 83
REPAIR........................................................................................ 83
TOOL RACKS........................................................................................ 85
REPAIR........................................................................................ 85
TOOL WRENCHES..................................................................................... 87
REPAIR........................................................................................ 87
BACK BRACES....................................................................................... 88
REPAIR........................................................................................ 89
ADJUSTMENT.................................................................................... 89
HYDRAULIC SYSTEM.......................................................................................... 90
SYSTEM OPERATION...................................................................................... 90
CYLINDER CIRCUIT HYDRAULIC SYSTEM................................................................. 90
PULLDOWN CIRCUIT HYDRAULIC SYSTEM (STANDARD)...................................................... 94
PULLDOWN CIRCUIT HYDRAULIC SYSTEM (AUTOMATED)..................................................... 96
GENERAL MAINTENANCE................................................................................... 97
HYDRAULIC SYSTEM CLEANLINESS...................................................................... 97
OIL REQUIREMENTS.................................................................................. 97
OIL AND FILTER CHANGES............................................................................ 97
WEEKLY MAINTENANCE CHECKS......................................................................... 98
OIL RESERVOIR REPAIRS............................................................................. 98
UNLOADER VALVE ADJUSTMENT......................................................................... 98
PRESSURE REGULATING (RELIEF) VALVE ADJUSTMENT..................................................... 98
CHAIN EQUALIZER RELIEF VALVE ADJUSTMENT........................................................... 99
SERVO VALVE....................................................................................... 99
COMPONENT MAINTENANCE.................................................................................101
HYDRAULIC PUMP OVERHAUL...........................................................................101
DISASSEMBLY...................................................................................101
CLEANING......................................................................................101
INSPECTION....................................................................................102
REASSEMBLY....................................................................................102
TEST PROCEDURE................................................................................104
MAIN VALVE BANKS..................................................................................104
GENERAL.......................................................................................104
DISASSEMBLY...................................................................................104
CLEANING, INSPECION AND REPAIR................................................................106
ASSEMBLY......................................................................................106
HYDRAULIC PULLDOWN MOTOR..........................................................................106
DISASSEMBLY...................................................................................106
CLEANING, INSPECTION AND REPAIR...............................................................108
REASSEMBLY....................................................................................108
DISASSEMBLY OF CHAIN EQUALIZER VALVE RELIEF VALVE CARTRIDGE.......................................108
HYDRAULIC OIL COOLER..............................................................................109
WEEKLY MAINTENANCE CHECK......................................................................109
1000 HOUR MAINTENANCE CHECK...................................................................109
YEARLY MAINTENANCE CHECK......................................................................109
AIR SYSTEMS...............................................................................................110
SYSTEMS OPERATION.....................................................................................110
GENERAL...........................................................................................110
MAIN AIR SYSTEM...................................................................................110
AUXILIARY AIR SYSTEM..............................................................................110
SAFETY............................................................................................112
GENERAL MAINTENANCE...................................................................................113
MAIN AIR SYSTEM GENERAL...........................................................................113
GENERAL...........................................................................................113
INTAKE AIR FILTER-BOX TYPE........................................................................113
INTAKE AIR FILTER-TUBULAR TYPE....................................................................113
FILTER REPLACEMENT............................................................................114
COMPRESSOR LUBRICATOR (VANE COMPRESSOR ONLY)......................................................114
FEED RATE.....................................................................................114
VISCOSITY GRADE...............................................................................115
LUBRICATOR DAILY MAINTENANCE CHECK............................................................115
LUBRICATOR SERVICE............................................................................115
LUBRICATOR PRIMING............................................................................115
COMPRESSOR RADIATOR...............................................................................116
SAFETY VALVE SETTINGS.............................................................................116
DRILLING PRESSURE.................................................................................116
AUXILIARY AIR SYSTEM..............................................................................116
AUXILIARY AIR COMPRESSOR..........................................................................116
MISCELLANEOUS COMPONENTS..........................................................................117
UNLOADER CHECK VALVE SERVICE..................................................................117
TANNER DE-ICER(OPTIONAL)......................................................................117
AIR TANKS.....................................................................................118
AIR TANK VALVES...............................................................................118
PRESSURE SWITCH...............................................................................118
FILTER........................................................................................118
ANTI-FREEZER..................................................................................118
MAINTENANCE PROCEDURE FOR AIR DRYER...........................................................118
DESICCANT CANISTER REMOVAL....................................................................119
PURGE VALVE REMOVAL...........................................................................120
AUXILIARY AIR COMPRSSOR (KELLOGG-AMERICAN)............................................................122
DISASSEMBLY OF PUMP...............................................................................122
FITTING AND REASSEMBLING..........................................................................123
MAIN AIR COMPRESSOR...................................................................................125
ROTARY VANE COMPRESSOR (ALLIS-CHALMERS)...........................................................125
1000 HOUR MAINTENANCE CHECK...................................................................125
4000 HOUR MAINTENANCE CHECK...................................................................126
BLADE PROTECTION IN IDLE UNITS................................................................129
ROTOR ALIGNMENT FOR REDOWELING................................................................130
ROTOR FIELD REDOWELING........................................................................130
ROTARY SCREW COMPRESSOR (A-C COMPRESSOR CORP.) KS-31-LU OR KS-27-LU...............................132
DESCRIPTION...................................................................................132
COUPLING ALIGNMENT............................................................................132
START-UP PROCEDURE............................................................................133
CONTROLS AND INSTRUMENTS......................................................................134
LUBRICATION SYSTEM............................................................................143
AIR FILTERS...................................................................................149
MAINTENANCE SCHEDULE..........................................................................151
DUST CONTROL..............................................................................................157
GENERAL MAINTENANCE...................................................................................157
DRILLING PLATFORMS AND DUST CURTAINS..............................................................157
FILTER AIR-BAG SYSTEM (AMERPULSE).................................................................157
DAILY MAINTENANCE CHECKS......................................................................157
MONTHLY MAINTENANCE CHECKS....................................................................158
SIX MONTH MAINTENANCE CHECKS..................................................................158
WATER INJECTION (USING WATER PUMP)................................................................158
WATER INJECTION (PRESSURIZED).....................................................................158
COLD WEATHER PROTECTION SYSTEM................................................................158
MAINTENANCE OF AMERPULSE..............................................................................160
OPERATING PRINCIPLES..............................................................................160
FILTER TUBE INSTALLATION..........................................................................160
PRINTED CIRCUIT TIMER TEST........................................................................161
SOLENOID VALVE TEST...............................................................................162
PULSE RECOMMENDATIONS.............................................................................162
HOPPER VIBRATOR...................................................................................162
LUBRICATION...............................................................................................164
LUBRICATION PROCEDURES................................................................................164
GENERAL...........................................................................................164
LUBRICANT CLEANLINESS.............................................................................164
AUTOMATIC SYSTEM LUBRICATION POINTS...............................................................164
LUBRICANT BENCHMARKS..............................................................................165
LUBRICATION CHARTS................................................................................165
GEARCASE AND RESERVOIR CAPACITIES.............................................................165
LOWER WORKS LUBRICATION.......................................................................165
MAINFRAME (PART 1)............................................................................167
MAINFRAME (PART 2)............................................................................168
MAST (PART 1).................................................................................169
MAST (PART 2).................................................................................170
MAST (PART 3).................................................................................171
LINCOLN AUTOMATIC SYSTEM..............................................................................172
TROUBLESHOOTING SYSTEMS...........................................................................172
AIR LOCKS.....................................................................................172
DIRTY SUPPLY LINES............................................................................172
ALL INJECTORS DO NOT FUNCTION PROPERLY........................................................172
AFTER VENTING, THE INDICATOR STEMS ON THE INJECTORS DO NOT RETURN TO THEIR NORMAL POSITION....172
FAILURE OF THE PUMP TO BUILD UP PRESSURE......................................................173
SLUGGISH PUMP OPERATION.......................................................................173
SLOW PRESSURE RISE............................................................................173
ASSEMBLY OF TUBING COMPRESSION FITTINGS.......................................................173
PRINCIPLE OF OPERATION PUMP AIR MOTOR.........................................................173
SERIVCE OF LOWER PUMPING UNIT.................................................................175
LUBRICATION...................................................................................176
INSTALLATION, OPERATING, AND MAINTENANCE INSTRUCTIONS.........................................176
TRABON AUTOMATIC SYSTEM...............................................................................180
LOCATING BLOCKAGE IN SYSTEM.......................................................................180
TERMINOLOGY...................................................................................180
PROCEDURE.....................................................................................180
TORQUE INFORMATION IN FOOT POUNDS.................................................................183
VANE TYPE MAIN COMPRESSOR LUBRICATOR OR BIT LUBRICATION...............................................184
OPERATION AND ADJUSTMENT..........................................................................184
TO START LUBRICATOR...........................................................................184
TO ADJUST LUBRICATOR..........................................................................184
SIGHT FEED UNIT...............................................................................184
PURGING OIL FROM PUMPING UNIT.................................................................184
CARE OF LUBRICATOR............................................................................185
TROUBLESHOOTING...........................................................................................186
GENERAL...............................................................................................186
DRILLING..............................................................................................187
ROTARY DRIVE UNIT.....................................................................................189
HOIST-PROPEL TRANSMISSION.............................................................................189
MAST..................................................................................................190
MAIN AIR COMPRESSOR (VANE TYPE).......................................................................190
MAIN AIR COMPRESSOR (SCREW TYPE)......................................................................193
AUXILLARY AIR COMPRESSOR..............................................................................196
HYDRAULIC SYSTEM......................................................................................197
HYDRAULIC OIL COOLER..................................................................................198
HYDRAULIC CYLINDER....................................................................................198
HYDRAULIC PUMP........................................................................................199
HYDRAULIC PULLDOWN MOTOR..............................................................................201
PRESSURE REGULATION AND PULLDOWN RELIEF VALVES........................................................202
HYDRAULIC CHAIN EQUALIZER PUMP........................................................................203
CONTROL VALVES........................................................................................203
UNLOADER VALVES.......................................................................................204
SERVO VALVES..........................................................................................205
AMERPULSE.............................................................................................206
APPENDICES................................................................................................207
GEAR INSPECTION.......................................................................................207
BOLT TORQUING.........................................................................................209
TORQUE WRENCH METOD...............................................................................209
TURN OF THE NUT METHOD............................................................................210
PINION AND COUPLING INSTALLATION......................................................................211
REMOVAL FROM MOTOR SHAFT..........................................................................211
MOUNTING PINION OR COUPLING ON SHAFT..............................................................211
LUBE BENCHMARKS.......................................................................................213
MULTIPURPOSE TYPE GREASE (MPG)....................................................................213
AIR COMPRESSOR (VANE TYPE) LUBRICANT (ACVL).......................................................214
AIR COMPRESSOR (PISTON TYPE) LUBRICANT (ACPL).....................................................215
CHAIN DRIVE LUBRICANT (CDL).......................................................................216
DRILL PIPE THREAD LUBRICANT (DPTL)................................................................217
MULTIPURPOSE OIL (MPO)............................................................................218
OPEN GEAR LUBRICANT (OGL).........................................................................218
REGULAR TYPE GEAR LUBRICANT (RGL).................................................................220
RUNNING WIRE ROPE LUBRICANT.......................................................................224
HYDRAULIC OIL FOR MINING MACHINERY (HYDO).........................................................225
RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRINCIPAL STRUCTURES ON BLAST HOLE DRILLS...........227
GENERAL...........................................................................................227
MAINTANENCE WELDING...............................................................................227
STRUCTURAL MATERIALS..............................................................................227
WELDING ELECTRODES................................................................................228
PREHEAT REQUIREMENTS..............................................................................230
REMOVAL OF CRACKS.................................................................................230
WELD GROOVE PREPARATION...........................................................................230
DRILL PIPE WELDING................................................................................230
WELDING TECHNIQUE.................................................................................232
WELD INSPECTION...................................................................................232
REPAIR OF BROKEN PARTS............................................................................232
METHODS OF REPAIR OF CRACKS.......................................................................232
PREVENTIVE MAINTENANCE CHECKLIST......................................................................233
LEVEL I INSPECTION................................................................................233
LEVEL II CHECKLIST................................................................................238
LEVEL III CHECKLIST...............................................................................240
SPECIAL DRAWINGS......................................................................................241
HOIST-PULLDOWN SHAFT..............................................................................241
PROPEL SHAFT......................................................................................241
IDLER SHAFT.......................................................................................241
HYDRAULIC MOTOR SHAFT.............................................................................242
SECOND INTERMEDIATE PULLDOWN SHAFT................................................................242
FIRST INTERMEDIATE PULLDOWN SHAFT.................................................................242
FIRST INTERMEDIATE PROPEL SHAFT...................................................................243
RH AND LH INTERMEDIATE PROPEL SHAFT...............................................................243
ROTARY GEARCASE SHAFTS (STANDARD).................................................................244
ROTARY GEARCASE SHAFTS (SUPER HEAVY DUTY).........................................................245
ROTARY UNIT SHIPPER SHAFT.........................................................................246
DRIVER THUMBLER SHAFT.............................................................................246
BUCYRUS 60/61R ELECTRIC BLAST HOLE DRILL MECHANICAL MAINTENANCE MANUAL – CAT ROTARY TRACK DRILL 60/61R – PDF DOWNLOAD:
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Bucyrus 60/61R Electric Blast Hole Drill Mechanical Maintenance Manual – CAT Rotary Track Drill 60/61R – PDF DOWNLOADBucyrus 60/61R Electric Blast Hole Drill Mechanical Maintenance Manual – CAT Rotary Track Drill 60/61R – PDF DOWNLOAD
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