Cat Bucyrus R506 - R2112 Service & Maintenance Instruction Manual - PDF DOWNLOAD

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SERVICE INSTRUCTIONS

SERVICE INSTRUCTIONS

unscrew large ram On small the cap set screw visible. Remove screw and withdraw cap. Press small plunger thru

To disassemble unscrew base. Witildraw large ram plWlger from R506 and both ram plungers from R2112. On the R2112 extend small ram plunger until the cap set screw is visible. Remove screw and withdraw cap. Press small ram plunger down thru large ram plWlger.

To replace the packing on the small ram plunger, remove the adaptor nut with a spanner wrench. Remove spring washer, male adaptor, ram packing, and female adaptor. Clean ram plWlger and remove parts. Replace female adaptor if scored. Slip the female adaptor on ram plunger and assemble the new packing one ring at a time to insure each being seated properly. Assemble male adaptor, spring washer and adaptor nut. Tighten the adaptor nut until the spring washer is compressed to one-half its original height.

the adaptor nut with male adaptor, packing, and female adaptor. Clean ram plWlger and parts. Replace female adaptor scored. Slip the female adaptor on ram plWlger and assemble packing at a each being seated Assemble male adaptor, nut. Tighten nut until washer is to one-half its original

CARRVfNC HANDLE 139-9

Center punch the adaptor nut to the ram plunger to prevent it from turning loose.

adaptor ram plunger prevent from loose.

replace of the large plunger, procedure for the small ram plunger. Dip the small ram plunger insert large ram plunger. Extend ram plunger so cap hole visible. cap of ram and tighten with set Dip the large plunger the plunger into the housing. Take caution not to cut the packing when starting into the housing.

To replace the packing of the large ram plunger, follow the same procedure as for the small ram plunger. Dip the small ram plunger packing in oil and carefully insert in the large ram plunger. Extend small ram plunger so that cap set screw hole is visible. Insert cap in top oi small ram plunger and tighten with set screw. Dip the large ram plunger packing in oil and careiully insert the plunger into the housing. Take caution not to cut the packing when starting into the housing.

Before check "0" ring. frayed Tighten firmly using

Before assembling base in housing check "0" ring. If frayed replace. Tighten base down firmly using spanner wrench.

SECTION R506

SIMPLEX RAM Nos. R506 ·R2112 .. Continued

MAINTENANCE SUGGESTIONS

the ram clean and free from nicks the unit is in the plunger should be maintain correct oil level. Use Simplex Hydraulic Jack Oil dewaxed minus 40o F. Never- use brake fluid.

Keep the ram clean and free from nicks (when the hydraulic unit is not in use, the ram or ram plunger should be retracted). Always maintain correct oil level. Use only Simplex Hydraulic Jack Oil - dewaxed - pour test minus 40o F. Never- use hydraulic brake fluid.

If are Jack Service Station. or facilities costly. Jack should capable of lifting in 1 Al" in

If you are notfamiliar with Hydraulic Jack mechanisms, may we suggest that you write us for the name of the nearest Hydraulic Jack Service Station. Improper repairs or testing facilities are costly. Every Jack should be capable of lifting its rated capacity, and should sustain the load without lowering in excess of 1 Al" in four hours.

It is important in repairing and maintaining hydraulic units

that a dean work place and clean tools be used. Any foreign substance within a hydraulic system may make it inoperative. Special tools are available for repairing the hydraulic units.

Any hydraulic system may inoperative.

All Simplex Jacks are inspected and tested before leaving the factory and are guaranteed against defects in material and workmanship. Any claims for adjustment are subject to our inspection and determination.

Simplex Jacks, returned to the factory for reconditioning or inspection, should be properly tagged, transportation charges prepaid, and if via freight, mark bill of lading "NOIDN-NOT -.WHEELED" to secure the lowest freight rate.

Jacks are inspected and tested before the factory and guaranteed against defects in material Any properly tagged, charges "NOIDN-NOT freight

AOAPTER NUT R2012-7A (SMALL)

FEMALE ADAPTER R2112-a (LARGE)

•• \1" PACKING R2012·9 (LARGE)

SERVICE INSTRUCTIONS

pump operate check RP6A, reservoir tube support remove screw. oil level screw add to Caution. Do fill level, RP6A, should in oil

sq. pipe Oil come to tom

If pump fails to operate check oil level for all models but RP6A, stand pump on reservoir tube support and remove filler screw. If oil level is below screw hole, add oil to filler screw level. Caution. Do not fill beyond screw hole level, on Model RP6A, pump should remain in horizontal position. Remove oil fill screw (3/8 sq. hd. pipe plug). Oil level should come to bottom of hole.

Before operating RP6A Pump make sure that solid 3/8" plug is replaced by "Breather Plug."

Before sure solid 3/8" is replaced

Pump Piston (See Figure 7J

Pump (See

Oil leakage around pump piston at pump gland india or piston cup. install new remove handle socket withdraw pump piston the about an inch pump housing (RP5-1). Loosen pump (RP5-9) of piston. Remove the pump packing (RP5-10) and the male adapter (RP5-11). Clean piston chamber (both small large diameters) thoroughly. (RP5-13D) and pump

brass and pump "0" ring (RP5-13C) from diameter. Slip the gland, male adapter over large diameter the then the on in into piston diameters are respective chambers. Lower the male onto its counterbored carefull one at sure first is on the male adapter other ring seated below. Thread down gland until it touches the packing (do punch of the thread prevent the gland from working socket.

Oil leakage around pump piston at pump gland indicates a worn or torn piston cup. To install a new piston cup, remove handle socket (RP5-6) and withdraw pump piston (RP5-13) until the piston head is about an inch above the pump housing (RP5-1). Loosen pump gland (RP5-9) and complete withdrawal of pump piston. Remove the pump packing (RP5-10) and the male adapter (RP5-11). Clean piston chamber (both small and large diameters) thoroughly. Remove pump piston cup (RP5-13D) and pump piston cup washer (RP5-13E). Assemble replacement cup, leather washer, brass washer and nut. Remove pump piston "0" ring (RP5-13C) from large diameter. Slip the pump gland, pump packing, and male adapter over the large diameter of the pump piston and then assemble the replacement "0" ring on RP5 only. Dip the piston in oil and carefully insert into the housing until both piston diameters are in their respective chambers. Lower the male adapter onto its counterbored shoulder and carefull y insert packing rings one at a time. Be sure the first ring is seated on the male adapter and that each other ring is seated on the one below. Thread down pump gland until it touches the packing rings (do not tighten). Center punch the ends of the thread to prevent the pump gland from working loose. Assemble handle socket.

Pump Valves (See Figures 1 & 3)

Valves (See Figures 1

Should the pump fail to supply pressure or should the pump piston be under pressure at all times, the pump valves need a cleaning. To clean, open release valve (RP3-4). Remove valve seal screw (3HJ-21) and valve seal (3HJ-24). With valve screw hole down, strike base of pump on bench so that balls and springs fall out of valve chamber. Inspect and clean valve chamber thoroughly. Do not nick or mar finish of valve seats. Clean pump valve balls and springs carefully in solvent. Do not stretch the springs. Replace rusted or corroded balls. To reassemble insert small ball, then small spring, then large ball and large spring; using the valve seal inserting tool (3ID-50), assemble the new pump valve seal, and

Should pump fail supply pressure or should pump piston be under pressure at all times, pump valves a release (RP3-4). Remove valve seal (3HJ-21) and With screw hole strike base of bench that balls and springs fall out of valve chamber. Inspect and clean valve chamber thoroughly. Do finish of pump balls springs in solvent. Do the springs. rusted or corroded balls. To reassemble insert small spring, and spring; using valve inserting (3ID-50), the new pump valve and

finally, the valve seal screw.

finally, seal screw.

This cleaning should be carried out in the pump valve circuits of both the small and the large diameter piston. If the valves fail to operate after the cleaning, it may be necessary to reseat the balis. Remove the springs and tap each ball lightly on its respective seat using the 1/4" ball seating tool (RP3-52) for the small ball and the 3/8" ball seating tool (RP3-51) for the large ball. Remove the balls to insure against sticking. Reassemble pump valve as before.

cleaning be pump both piston. If the valves fail operate after the cleaning, may necessary Remove the springs each ball (RP3-51) for large ing. pump as before.

Release Valve (See Figure 2)

Release Va've Figure 2)

A fail or load the lease is dirty. release (RP3-4), release gland "release valve (303A-40A) release valve ball. Clean release slight the of the screw not screws should be replaced. Reseat the release ball using the 1/4" ball seating tool (RP3-52) and insert the release valve using the valve packing inserting tool (303A-60).

A ram will fail to lift or hold a load if the pump release valve is dirty. Remove release screw (RP3-4), release screw gland (RP3-5), "release valve packing (303A-40A) and release valve ball. Clean and inspect valve seat and release screw. A slight depression in the end of the screw is not harmful. Burred screws should be replaced. Reseat the release ball using the 1/4" ball seating tool (RP3-52) and insert the release valve using the valve packing inserting tool (303A-60). Reassemble release screw.

Safety By-Pass Valve (See Fjgure 2)

Safety By-Pass Valve (See Figure

a fails to or hold load after the release valve and valves have been the by-pass valve seal screw (3HJ-21), (3HJ-24), and the socket wrench remove e safety valve screw With hole tap pump to

If a ram fails to lift or hold a load after the release valve and pump valves have been checked, the safety by-pass valve maybe dirty. Remove valve seal screw (3HJ-21), valve seal (3HJ-24), and using the knurled socket wrench (RP3-50) remove th e safety valve screw (RP3-7B). With hole down tap pump housing to

RP5-9 RP5-10 RP5-11

RP5-6A (LONG) RP5-12

RP6A-2

Figure 1 Section Showing P=p Piston and Pump Valve for S=a1l Diameter of P1.unp Piston

RP5-9 RP5-11

RP5-6A (LONG) RP5-12

3I-U-23B RP5-14 RP6A-2

Section P=p and Pump Valve for S=a1l Diameter of P1.unp Piston

remove (RP3-7A), (RP6-7C)

RP6A and ball is lightly the seat. RemovE' ba Reassemble valve spring plunger, spring and calibrated pressure the release and the until sequence until gauge records a 12,500 Reassemble screw

remove safety valve spring (RP3-7A), safety valve needle (RP6-7C) and ball. (RP5 has ball, RP6 and RP6A have needle point.) Clean and inspect ball seat. If seat is marred, reseat by lightly tapping ball on the seat. RemovE' ba II to insure against sticking. Reassemble safety valve ball, spring plunger, spring and screw. Connect a pressure gauge calibrated in psi to the pump high pressure outlet. Tighten the safety valve screw a turn, close the release valve, and stroke the pump piston until the gauge reaches a ma..--rimum reading. Repeat this sequence of opera'tions until the gauge records a maximum reading of 12,500 psi. Reassemble valve seal and valve seal screw and remove gauge.

Large Diameter Pump Piston By-Pass Valve on Models RP6 & 6A (See Figure 2)

Diameter Piston By-Pass Models & (See

Figure

On models RP6 and RP6A remove high speed by-pass valve assembly clean and inspect ball seat, lightly tap ball if seat is marred, replace parts. No resetting is necessary. Setting screw RP6-18A must be turned in until it bottoms; this automatically sets bypass to the proper setting.

On RP6A remove clean ball seat, parts. resetis necessary. screw RP6--18A must be it byto setting.

3HJ -23B (1/4'1

-23B (1/4'1

BY-PASS

VALVE FOR LARGE DIAMETER......., IOF PUMP

PISTON

Valve

Valve Valve

large Diameter Pump Piston By-Pass Valve on Model RPS (See Figure 3)

large Diameter Pump on Model Figure

If the ram does not raise faster under no loading or light loading than it does under heavier loading, the large diameter pump piston by-pass valve is dirty. Remove parts, clean and inspect ball seats as explained above. Remove valve seal screw (3HJ-21), valve seal (3HJ-24), and the springs and balls from the small diameter pump valve hole. Reassemble large ball, large spring, valve seal and valve screw, leaving out small ball and spring. Connect a pressure gauge to the high pressure outlet. Reassemble by-pass valve ball, spring plunger, spring and screw. Following the same sequence of operations as for the overload valve, set the by-pass valve to a maximum pressure of 900 psi. Reassemble valve seal and valve seal screw and remove gauge. Reassemble small ball and small spring in the small diameter pump valve hole.

the does not under no loading large by-pass parts, inspect ball as screw (3HJ-21), (3HJ-24), and the and the diameter valve hole. large ball, valve screw, leaving presthe Reassemble ball, plunger, spring screw. the sequence as by-pass valve a Reassemble seal remove gauge. Reassemble and spring the valve

MAINTENANCE INSTRUCTIONS

INSTRUCTIONS

Keep all parts clean and free from nicks (when the hydraulic unit is not in use, the ram or ram plunger should be retracted). Always maintain correct oil level. Use only Simplex Hydraulic Jack Oil- dewaxed - pour test mmus 40°F. Never use hydraulic brake fluid.

If you are not familiar with Hydraulic Jack mechanism, may We suggest that you write us for the name of the nearest Hydraulic Jack Service Station. Improper repairs or testing facilities are costly. Every Jack should be capable of lifting its rated capacity, and should sustain the load withoutlowering in excess of 1/8" in four hours.

all parts clean hydraulic unit is use, the ram ram should retracted). level. dewaxed mmus are Hydraulic Jack nism, We suggest that you write name of costly. capacity, should the load of 1/8" in hours.

is maintaining clean and Any hydraulic make it available for the hydraulic units.

It is important in repairing and maintaining hydraulic units that a clean work place and clean tools be used. Any foreign substance within a hydraulic system may make it inoperative. Special tools are available for repairing the hydraulic units.

X-2696

Figure 2 Section Showing Release Valve and Safety By-Pass

Figure 3 Section Showing Pwnp Valve and By-Pass Valve for Large Dia=eter of PuInp Piston

303A-39B (3/16" BALL)

Figure

Step 2. Lightly' on Tings an<I rings U;tO grooves of sleeve (into of retainer 'for S1Zes ",

108 Female sleeve is normally mounted on motor or For rings inserted) on ahaft.and check orientation to'sSsurej('0;,"

heat to hubs uniformly, preferably

' hubs. For sizes 108 and larger, place retainer gaskits'arid.'

tiOn.'oi in accordance With Dimension from: EnginWhigpata hubs with straightedge at '" '. onto hnbs,carefuIly"enPgingteetlJ'>PUice :ti':F';;i; sleeves

"

'.to :tighten fastenersuniforinIY- ·To !acilitate disassembly, sleeve flanges {sizes 103 and };?:,:;':;;' ;

BASI C INSTALLATION, (For Standard Series F

INSTALLATION,

and ,;. " ,,- sn-;J, -ifugfs"""" er', {witJi' hub "0" ring seated in .;8 'ril!g and retainer '{with "0:' ring inserted) and gasket' "f(an·;i"clJeck.,,,

.. with short

shrinkpts;apply heat to hubs submerged In'9il iiOt exceed', ,:".'••."

.":,·'C.,',::.e,,,ytapeI".;.or, feelergauge'at.90O, mtervals."A1so strlUght edge at 90°., pomts.c

MAINTENANCE

holes so that flange bolts can be used to separate sleeves. For sizes' • 108 lU1d larger bolt seal retainers to sleeves.

'.' Step 7.'Retriove bOth DrYseaI lube plugs andadd grease in suffiCient amount to overflow with lubricant holes in horizcintalposition •.Installlube plugs and seat securely.

flange bolts can be used to separate sleeves. For sizes' • 108 '.' Step in in in

'.;: For verticaIcouplings, remove one Dryseal plug in each coupling half andcarefully insert thin probe underupper hubseaI to assure complete filling.:> •. ..•.. .' .' Step 8.' Ready to go! InstaIledand hibTicated in accordance .with the instructions. your Amerigear Series F Coupling is prepared for a long life of dependable, low maintenance service: "',"

.The Serle;F Coupling prope;ly operate 3 to S years before recommended _'. ", .',' _. " :,', :0

···.·Todisassemble remove flange fasteners. separate'sIeeves('iisejack:' " 103 and larger ),slide 'and gear .·teeth 'step ;:#4

Shafts •• di' coupling; remove both lube and add greaSe in. with lubricant holes in horizontal position. FOr reco1nnlended lubrl" quantities, see next page. ,

INSTRUCTIONS

MAINTENANCE INSTRUCTIONS

Couplings)

and C Flexible Couplings)

''''':",;",'';'r"

<' _. "._- ': ',-, ';':', Step";'. For sizes' .sleeve "0" rings in sleeve counter bores .,--theri press seal retainer assembly in tips toOL Seat snap rings in a winding motion; Recheck to assure snapringstu'e. sizes 108 and larger;. bolt seal end'platest<i sleeve. For vertical couplings,remove one Dryseal'lube plug and carefully insert probe underupper hub -seal to assure complete

MAINTENANCE

in tips toOl; Seat snap rings in ' ' The Amerigear Series installed '.and a motion; assure,.normaIly snapringstu'e, sizes 108 and-ment check and re-lubrication. To disassemble, ?'nO; .•.... " .• sleeve off hubs, clean out old lubricant and inspect seals insert probe underupper hub -seal to assure complete starting Step #Sunder installation

'.'

•.•. TheknerigearSeries '-.'-.

,normally operate for 3 to SyearS 'ment check and re-lubrication. To disassemble, .: sleeve off hubs, clean out old lubricant and inspect seals starting Step #S under installation pi-Op;;'aii&;

ment of shafts is aSsured and it is not practical to r.c;mo··

Step 8. Ready to go! InstalIed and lubncated In both Dryseal lube plugs,· Position lube holes in horizoiitai coroancelNith theinstructions. your Amerigear Series C. sufficient amount to overflow. For recommended lubneantsand

Installed and lubricated in ac· coidancelN"ith the instructions. your Amerigear Series C long life of dependable, .trouble-freesennce. ' '.,-"," ,:'" ,. :'

•. ment of shafts is aSsured and it is not practical to r.c;mov: both Dryseal lube plugs,· Position lube holes in sufficient amount to overflow, For recommended IUbneantsand '

next page.,... .' ,L'. . ... , 101 are supplied without lube p1ul1_1ubricate per ".-

',

Amerlgellr RECOMMENDED LUBRICANTS

A grease lubricant which is stable and will not centrifuge is normally used with Amerigear Couplings. The following lubricants are provided as general recommendations only equivalents may also be used. The listing is not intended to be complete or necessarily current due to continuous research and improvements by the various manufacturers.

A which is stable not centrifuge normally used with lubricants are as recommendations also be is not to complete necessarily current due to by

RECOMMENDED QUANTITIES

SERIES F, FM,

SERIES

SERIES

C, CM, CA

SERIES C, CM, CA

For Series CMS. CAS, use H the commended.

For Series CS. CMS. CAS, use )'2 the quantities recommended.

These instructions have been prepared to assist the operator or electrician in charge of maintenance of the machine, to adjust and care for the electrical equipment properly. The various items of electrical equipment used on Bucyrus-Erie machines are the products of reputable electrical manufacturing concerns adapted to service on excavating equipment. Included in the instructions o.iginally furnished with the machine are a number of bulletins furnished by the manufactu.er of the electrical equipment which describe the various items and give the recommended adjustment and maintenance procedure. Such instructions must be carefully foHowed if satisfactory oper-ation of the elect.ical equipment is to be obtained.

Most Bucyrus-Erie electricaiiy-operated machines may be placed in one of two classifications. Small electric machines are usually powe.ed with a single induction motor in the same position, and serving the same purpose, as the :nter-nal combustion engine of the standard friction machine. Machines of larger size are gener-ally of the Ward-Leonard (variable voltage generator-) control type. Most machines of this type have c singie induction (or synchro:lcus) iTIotor dri'ving three direct-cuaent gener-ato:-s (two on draglines). A separate, constant voltage exc:te:- ge:,erato, fu,nishes the cor:rrol fieid CU;:Te:1t for the generato:-s and excitation for the .shunt motors.

The a:-:::o:ture c:rcuit 0: each is co;;.necree directlv to the afffi2tt.!!"e ci:-c:u!t or 2 neavy-du"IY direct-current motor- without anv s\.\·itcnes or orner contr-oI i:: the CU,t. The speed. as well as direction or rotatio:, of each ::1ator. is regulated by ar; individt.:al co:-,troller at the oper-2tor's position.

Use Approved Cable and Install It Properly

Power is carried to electric machines by a flexible, r-u!:>ber--covered cable especiaEy developed by cable manufacturers for excavating sen'ice. This cable is the "life line" of the machine and must be p:-operly installed and ca:-efuHy handled to ensure cOl"ltinuous service and minimum hazard.

Remember that the cable carnes the full voltage of the supply liOle and must be handled carefully. Protect the cable from falling rocks or other damage. Do not let the cable rest in pools of water or become buried under soil or stones. Handle the cable with extreme caution, taking care that it is not dragged around comers or over sharp stO:1es. Coiling the cable in a figure eight permits laying out or taking in cable without subjecting it to sharp bends. There are several methods for installing the cable. The best one to use is dependent 0:1 iocal power- conditions and safety rules. Full details of installation should be discussed with your power company but the foilow{ng points must be observed to ensure maximU:T: safety.

The cable used should be provided with some sort' of ground cortnec:ion such as a fourth duc:or. three individual grot:nd 'wires. woven cooper br-2id sheath around each conductor, or som·e combination of the above. Whichever ground co"nec:tioOl is used must be kept continuous, and whenever the cable is spliced, a carefully soldered connec:tioOl in the ground connection must also be made. The g.ound con"ection at the machine end of the cable should be carefully bonded to the base, making sure that all paint, ,ust or- dirt has bee41 scraped of! the metal to ensure bood contact. The ground connection at the pole e:1d of the ca81e should be con:lec:ec to some lo·u:-:-esis".:c::ce such 2S an ae:-:al groul1d lZ:le (grou:1ded zt inter,'alS along the line) and ca:-:-iec :::e: sU::lplv ::-a:lsro:-::1e:-s 1.\,"here ·c CO:1:1ec:e:: ta the tiansio:-:ner grounc: a res:s:ance. Be Si.1:":' rOGs 2:-e c::ver: ;:::0 the eal'"th to ii depth sur:':::Jenr :0 ens:..::-e pe:-:r:zne:1t moisture. Conrae: of tne provided should not gre2tly exceed 25 o?1ms and each ground should be testec reguiarly to if there is 271V te71denc\' fo, the resistance to increase.

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.