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
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