Cat Bucyrus 60R 61R Electric Blast Hole Drill Mechanical Maintenance Manual BI615839 – PDF DOWNLOAD

Description

Cat Bucyrus 60R 61R Electric Blast Hole Drill Mechanical Maintenance Manual BI615839 – PDF DOWNLOAD

FILE DETAILS:

Cat Bucyrus 60R 61R Electric Blast Hole Drill Mechanical Maintenance Manual BI615839 – PDF DOWNLOAD

Language : English
Pages : 246
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Cat Bucyrus 60R 61R Electric Blast Hole Drill Mechanical Maintenance Manual BI615839 – 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 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 CAUTION’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
  notdetailed in this manual.

TABLE OF CONTENTS:

Cat Bucyrus 60R 61R Electric Blast Hole Drill Mechanical Maintenance Manual BI615839 – 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 1 7
Leve ling 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
” BUCYRUS-ERIE COMPANY, 1984
BI615839
Rotary Guide Frame (Standard) 59
Adjustment 60
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 41
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 B Repair SS
Rotary Gearcase (Super Heavy Duty) 57
Drive Shaft Adjustment 5 7B
Repair 57B
Rotary Motor (Standard Gearcase) 5 7E
Rotary Motor (Super Heavy Duty Gearcase) 57E
Rotary Coupling _ 5 7F
Repair 57F
Rotary Shock Sub 5 7F
Repair 58
BI615839
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
l CHAPTER 3 – AIR SYSTEMS
Section 1 · SYSTEMS OPERATION
General 95
Main Air System 95
Auxiliary Air System 95
Safety 97
Section 2 GENERAL MAINTENANCE
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
U nloader 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
BI615839
Rotary Screw Compressor (Allis-Chalmers) 120
Description 120
Coupling Alignment 120
Start-Up Procedure 121
Controls and Instruments 122
Lubrication System 12 7D
Air Filters 13 3
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
< BUCYRUS-Er!IE cc ~PANY 1984
BI615839
Appendix A2 · BOLT TORQUING
Torque Wrench Method 2B
Turn-Of-The-Nut Method 2C
Appendix A3 – PINION AND COUPLING INSTALLATION
Removal For Motor Shaft 3A
Mounting Pinion or Coupling Shaft 3A
Appendix A4 – LUBE BENCHMARKS
Multipurpose Type Grease (MPG) 5A
A ir Compressor (vane type) Lubricant (ACVL) 6A
Air Compressor (piston type) Lubricant (ACPL) 7 A
Chain Drive Lubricant (CDL) SA
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; 17A
Appendix A5 · RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRI:\’CIPAL
STRUCTURES OK 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 24A
Weld Inspection 24A
Repair of Broken Parts 24A
Methods of Repair of Cracks 24A
Appendix A6 · PREVENTIVE MAINTENA ~CE CHECKLISTS
Level I Inspection 25A
Level II Inspection 30A
Level III Inspection 32A
Appendix A 7 – SPECL\L 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
BI615839
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
Locatirig 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 1 72
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
Amerpulse-E, 191
APPENDICES
Appendix Al -GEAR INSPECTION lA

Questions? Email us: [email protected]

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V