Cat Bucyrus 65R 67R Electric Blast Hole Drill Mechanical Maintenance Manual BI005543 – PDF DOWNLOAD
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Cat Bucyrus 65R 67R Electric Blast Hole Drill Mechanical Maintenance Manual BI005543 – PDF DOWNLOAD
Language : English
Pages : 679
Downloadable : Yes
File Type : PDF
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Cat Bucyrus 65R 67R Electric Blast Hole Drill Mechanical Maintenance Manual BI005543 – PDF DOWNLOAD
FOREWORD:
- The purpose of this manual is to provide information concerning the general maintenance of the
65/67-R rotary blast hole drill. - The 65/67-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 trans mission and the machinery house. The machinery house encloses the majority of
the mechanical equip ment 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 during operation or
maintenance. Always read the CAUTION note carefully and use extreme care while performing that
particular function. - WARNING indicates a possible hazard to the machine or its components if the proper procedures are
not followed. Whenever the word WARNING appears, special attention should be given to prevent
possible equipment damage. - NOTE is used to stress a point or to give additional information concerning the procedure
being dis cussed. - These CAUTION’s and WAR ING’s are not all-inclusive. Itis impossible for Bucyrus-Erie Company to
know, evaluate, and advise maintenance and service personnel in every conceivable way a
service operation might be performed and of the resulting possible hazardous consequences of
each method. It is therefore extremely important that anyone who uses a service procedure or tool
which is not recommended by Bucyrus-Erie Company to first satisfy himself that the service
procedure or tool he chooses will not jeopardize his own safety, the safety of others, or cause
machine or component damage. - Every effort has been made to make this manual as complete and accurate as possible at
the time of publication. Bucyrus-Erie Company, a Division of Becor Western Inc.,
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 65R 67R Electric Blast Hole Drill Mechanical Maintenance Manual BI005543 – PDF DOWNLOAD
CHAPTER 1 – MECHANICAL MAINTENANCE
PAGE
Section 1· MAINTENANCE PROCEDURE
General , 1
Maintenance Schedules and Reports ‘ 1
Safety 2
General 2
In-Operation Maintenance ” 2
Precautions Before and During Maintenance Work 2
Section 2 – LOWER WORKS
Crawler Belts 5
Adjustment ‘” ” 5
Link Replacement 6
Belt Replacement 7
Lower Rollers 7
Repair 7
Upper Rollers 8
Repair 9
Drive Tumblers 9
Repair 9
Take-Up Tumbler 10
Repair 10
Crawler Frames ‘” 11
Repair 11
Axles 13
Repair 14
Propel Final-Drive Chains 14
Repair 14
Adjustment 15
Section 3 – MAINFRAME
Mainframe and Mast Support ‘” ” 17
Repair 17
Leveling Jacks 17
Repair 18
Machinery House 19
Repair 19
House Ventilation Fan and Filter ” 19
Walkways and Ladders ” ‘” , ” 19
Operator’s Cab ” 19
Operator’s Seat 19
Operator’s Controls 20
Ventilation Unit ‘” 20
Hoist-Propel Gearcase 20
Repair 20
Removal and Installation of Gearcase 21
Gearcase Suspension ‘ 21
Hoist-Propel Gearcase Disassembly and Assembly ” 22
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Hoist Shaft 23
Second Intermediate Shaft 24
First Intermediate Shaft 25
Idler Shaft 26
Propel Shaft 26
Propel Clutches 27
Hydraulic Motor Shaft 29
Electric Hoist-Propel Motor 30
Repair 30
Propel Machinery 30
Repair 30
First Intermediate Shaft 30
Second Intermediate Shaft 32
Propel Chain Adjustment , 33
Hoist Brake 34
Adjustment 34
Repair 35
Propel Brakes 35
Adjustment 35
Repair 36
Hoist Clutch Lever 37
Adjustment 37
Repair 37
Hydraulic Pulldown Motor Clutch Lever 39
Adjustment , 39
Repair 39
Depth Indicator Drive 40
Cable Reel 40
Repair 41
Section 4 – MAST
Mast Structure 45
Repair 45
Mast Lock Latch 45
Repair 46
Rotary Gearcase (Standard) 47
Adjustment 47
Repair 49
Rotary Gearcase (Super Heavy Duty) 51
Drive Shaft Adjustment 53
Repair 53
Rotary Motor (Standard Gearcase) ” 56
Rotary Motor (Super Heavy Duty Gearcase) 56
Rotary Coupling ” ‘” 57
Repair 57
Rotary Shock Sub ” 57
Repair 58
Rotary Guide Frame 58
Adjustment , ” ‘” ” 59
Repair 62
Pulldown Chains 64
Adjustment 64
Repair 64
Pulldown Chain Equalizer 66
Repair ” 66
Tool Racks 68
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Repair 68
Tool Wrenches 70
Repair 70
Back Braces 71
Repair 72
Adjustment 72
Pipe Positioner 72
CHAPTER 2 – HYDRAULIC SYSTEM
Section 1- SYSTEM OPERATION
Cylinder Circuit Hydraulic System 75
Pulldown Circuit Hydraulic System 77
Section 2 – GENERAL MAINTENANCE
Hydraulic System Cleanliness 79
Oil Requirements , 79
Oil and Filter Changes 79
Weekly Maintenance Checks 80
Oil Reservoir Repairs 80
Prestart Inspection 80
Hydraulic Systems Tests ” ” 80
Pulldown Pump Charge Pressure ” , 80
Pulldown Motor Case Leakage 80
Hot Oil Shuttle Relief 82
Pulldown Pump Main Relief Check 82
Sequence Valve (Force Limit Control) Check 82
Chain Equalizer Pump Relief Check 82
Load Relief Check 83
Control Pressure Check 83
Main Relief Setting of 3-Spool
(Mast/Winch/Pipe Rack) Valve Check 83
Pipe Rack Selector Check 83
Cable Reel Check 84
Back Brace Lock Pin Check 84
Mast Angle Lock Pin check 84a
Mast Latch Control Check 84a
Dust Curtain Control 84b
Casing Tong Control 84b
Tool Wrench Control 84b
Leveling Jack Operation (Manual Mode) ‘” 84b
Leveling Jack Operation (Auto-Level Mode) 84b
Auxiliary Winch 84b
Pipe Rack Control 84b
Mast Hoist Control 84c
Section 3 – COMPONENT MAINTENANCE
Hydraulic Pump Overhaul (Cylinder Circuit) 85
Disassembly ” ” 85
Cleaning ” 86
Inspection 86
Reassembly , 86
Test Procedure 89
Hydraulic Cable Reel Motor ~ ” 89
Disassembly 89
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Cleaning, Inspection and Repair 90
Reassembly 90
Hydraulic Oil Cooler 91
Weekly Maintenance Check 91
1000 Hour Maintenance Check 91
Yearly Maintenance Check 91
Hydraulic Pulldown Circuit Pump 91
Removal of Relief Values 91
Removal of Inspection of Charge Pump 92
Replacement of Shaft Seal 93
CHAPTER 3 – AIR SYSTEMS
Section 1 – SYSTEMS OPERATION
General 95
Main Air System 95
Auxiliary Air System 95
Safety 95
Section 2 – GENERAL MAINTENANCE
Main Air System 97
General 97
Intake Air Filter – Box Type 97
Intake Air Filter – Tubular Type 97
Filter Replacement 98
Compressor Radiator 98
Auxiliary Air System 98
Auxiliary Air Compressor 98
Miscellaneous Components 99
Unloader Check Valve Service 99
Air Tanks 100
Air Tank Valves 100
Pressure Switch 100
Filter 100
Anti-Freezer 100
Section 3 – AUXILIARY AIR COMPRESSOR (COMPAIR-KELLOGG B352)
Disassembly of Pump 101
Fitting and Reassembling 102
Section 4 – AUXILIARY AIR COMPRESSOR (COMPAIR-KELLOGG B462)
Head Value Service 105
Pistion Ring Service 105
Overhaul Procedure 106
Reassembly 106
Section 5 – ROTARY VANE COMPRESSOR (A-C COMPRESSOR CORP )
1000 Hour Maintenance Check 109
4000 Hour Maintenance check 110
Blade Protection in Idle Units , 112
Rotor Alignment for Redoweling 112
Rotor Field Redoweling 113
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Section 6 – ROTARY SCREW COMPRESSOR (A-C COMPRESSOR CORP KS-31-LU or KS-27-LU)
Description 115
Coupling Alignment ‘” 115
Start-Up Procedure 116
Controls and Instruments 117
Lubrication System 123
Air Filters 129
Maintenance Schedule 130
CHAPTER 4 – DUST CONTROL
Section 1- GENERAL MAINTENANCE
Drilling Platforms and Dust Curtains 135
Filter/Clone’~1 System (Tipton) 135
Daily Maintenance Checks 135
Monthly Maintenance Checks ” , 135
Six Month Maintenance Checks 135
Water Injection ” , 136
Operation 136
Section 2 – MAINTENANCE OF FILTER/CLONE’E> (TIPTON)
Operating Principles , 139
Maintenance , 139
CHAPTER 5 – LUBRICATION
Section 1 – LUBRICATION PROCEDURES
General , 141
Lubricant Cleanliness 141
Automatic System Lubrication Points 141
Lubricant Benchmarks 142
Lubrication Charts
Gearcase and Reservoir Capacities 142
Lower Works 143
Mainframe (Part 1) , 144
Mainframe (Part 2) 145
Mast (Part 1) ” ‘ 146
Mast (Part 2) , 147
Mast (Part 3) 148
Section 2 – LINCOLN AUTOMATIC SYSTEM
Troubleshooting Systems 149
Air Locks 149
Dirty Supply Lines 149
All Injectors Do Not Function Properly 149
After Venting, the IndIcator Stems on the Injectors
Do Not Return to Their Normal Position 149
Failure of Pump to Build Up Pressure 150
Sluggish Pump Operation ~ 150
Slow Pressure Rise 150
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Assembly of Tubing Compression Fittings 150
Principle of Operation – Pump Air Motor 150
Service of Lower Pumping Unit , 152
Lubrication 153
Installation, Operating, and Maintenance Instructions , 153
CHAPTER 6 – TROUBLESHOOTING
General ” 157
Drilling 157
Rotary Drive Unit ‘ 160
Hoist-Propel Transmission 160
Mast 161
Main Air Compressor (vane type) 161
Main Air Compressor (screw type) 164
Auxiliary Air Compressor 167
Hydraulic System ” ‘” 168
Hydraulic Oil Cooler 169
Hydraulic Cylinder 169
Hydraulic Pump (Cylinder Circuit) 169
Hydraulic Pump (Pulldown Circuit) 170
Hydraulic Cable Reel Motor 172
Hydraulic Chain Equalizer Pump ” 173
Filter/Clone~) 173
APPENDICES
Appendix Al – GEAR INSPECTION 1A
Appendix A2 – BOLT TORQUING
Torque Wrench Method 3A
Turn-Of-The-Nut Method ” 4A
Appendix A3 – PINION, BRAKE DRUM, AND COUPLING INSTALLATION
Removal From Motor Shaft 5A
Mounting on Shaft 5A
Appendix A4 – LUBE BENCHMARKS
Multipurpose Type Grease (MPG) ” ‘” 9A
Air Compressor (vane type) Lubricant (ACVL) 10A
Air Compressor (piston type) Lubricant (ACPL) llA
Chain Drive Lubricant (CDL) 12A
Drill Pipe Thread Lubricant (DPTL) 13A
Multipurpose Oil (MPO) 14A
Open Gear Lubricant (OGL) 14A
Regular Type Gear Lubricant (RGL) 16A
Running Wire Rope Lubricant (RWRL) 20A
Hydraulic Oil for Mining Machinery (HYDO) 21A
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Appendix A5 -RECOMMENDED PROCEDURES FOR MAINTENANCE WELDING OF PRINCIPAL
STRUCTURES ON BLAST HOLE DRILLS
General 23A
Maintenance Welding 23A
Structural Materials 23A
Welding Electrodes 24A
Preheat Requirements , 26A
Removal of Cracks 26A
Weld Groove Preparation 26A
Drill Pipe Welding 26A
Welding Technique 28A
Weld Inspection 28A
Repair of Broken Parts 28A
Methods of Repair of Cracks 28A
Appendix A6 – PREVENTIVE MAINTENANCE CHECKLISTS
Level I Inspection 29A
Level II Inspection 34A
Level III Inspection 36A
Appendix A7 – SPECIAL DRAWINGS
Hoist-Pulldown Shaft 37A
Propel Shaft 37A
Idler Shaft 37A
Hydraulic Motor Shaft 38A
Second Intermediate Pulldown Sh,aft 38A
First Intermediate Pulldown Shaft 38A
First Intermediate Propel Shaft 39A
RH and LH Second Intermediate Propel Shafts 39A
Rotary Gearcase Shafts (Standard) 40A
Rotary Gearcase Shafts (Super Heavy Duty) 41A
Rotary Unit Shipper Shaft 42A
Drive Tumbler Shaft 42A
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