Service Manual P/N 419395 REV. 4 Model SD345 Hydraulic Track Drill Bucyrus Mining Equipment, Inc. 3501 S. FM Hwy 1417 Denison,Texas 75020 USA BI621947
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PARTS ORDERINGAND PRODUCT SUPPORT
Use only genuineBucyrus parts in the maintenance, rebuild or repair of these machines.The manufacturer shall have no liability as to any unauthorized modification of machines or parts. The manufacturer is also not obligated or liable for any machines or parts that have been improperly handled; that have not been operated, maintained or repaired according to furnished manuals or other written instructions, and that have been operated with other than genuineBucyrus parts or authorized OEM components.
IDENTIFICATION OF THE MACHINE
Always furnish the Model Number and Serial Number when ordering parts.This information is found on the machine nameplate.
PART NUMBERAND DESCRIPTION
In addition to the Model and Serial Number, always give the part number and description of each part ordered. If there is any doubt as to the correct part number and description, furnish a dimensioned sketch or return the part to be replaced, transportation charges prepaid.Your cooperation in furnishing as much information as possible will assist us in filling your orders correctly and in the shortest possible time.
SHIPMENT
Unless otherwise instructed, all shipments will be made via motor freight collect, freight forwarder or UPS prepaid and charged on our invoice. Shipments cannot be made on open account until your credit has been approved by our accounting department.
PARTS ORDERING
In NorthAmericaTelephone 1-800-854-9030
orTelefax 1-800-582-6570
Telephone (903) 786-2981
Telefax (903) 786-6407
PRODUCT SERVICEANDWARRANTY
In NorthAmericaTelephone 1-800-258-0009
Telephone (903) 786-2981
Telefax (903) 786-6408
Bucyrus Mining Equipment, Inc.
3501 S. FM Hwy 1417, Denison,TX 75020 www.bucyrus.com
© 2010Bucyrus International, Inc.
All Rights Reserved
BI621947
NOTE
WARNING:
BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1. Failure to do so may result in dangerous practices which can cause equipment damage, serious personal injury or death.
Service personnel must be familiar with the controls and operation of the machine. Read and understand the start-up, shutdown and control functions of the operator manual.
CAUTION:
DO NOT weld on any part of the machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. On machines equipped with electronic engine, disconnect the connections to the Electronic Control Module (ECM) on the engine before welding.
Do not disassemble components that are under warranty, as this will void the warranty on that component.
Introduction i
Introduction
Fig. i-0Caterpillar C9 Engine ECMs
Specifications are subject to change without notice. Information contained in this manual was up to date at the time of printing. Revised 08/2010 BI621947
ii Introduction Notes BI621947
Standard Features & Options
Track Undercarriage
Hydraulic motor-driven compact planetary gear drives with manual disconnect for towing. 15 in. (380 mm) wide, overlapping, triple grouser tracks with mud/snow relief. Relief grooves are also provided on the sprocket. Hydraulic cylinder controlled track oscillation and hydraulic released, spring applied disk brakes. Tram speed is 2.5 mph (4.02 km/hr.)
Engine
Caterpillar C9, six (6) cylinder, electronically controlled, water-cooled, turbocharged and air-to-air after-cooled 275 hp diesel engine. The engine speed is automatically controlled by power demand.
Hydraulic System
Two (2) direct driven pressure-compensated variable displacement, axial piston pumps, two (2) fixed displacement traction drive motors and a variable displacement compressor drive motor.
Air System
300 cfm Gardner-Denver Rota-Screw Compressor driven by a variable displacement axial piston hydraulic motor. Pressure capability to 150 PSI.
Drill Feed
Model UHF14 Chain Feed - standard on Model 345, powered by a hydraulic piston motor complete with a power centralizer and manual drill steel rack. The feed will manually change 14 ft. (4.3 m) drill steel or drill single pass with 16 ft. (4.9 m) drill steel without a hose reel.
Rock Drill
Model HPR4519 hydraulic percussion drill (standard) for holes up to 4 in. (102 mm) diameter, using 1 1/2 or 1 3/4 in. (38 or 45 mm) drill steel. Model HPR5123 drill optional for up to 5 in. (127 mm) using 2 in. (51 mm) drill steel.
Boom
12 ft. (3 m) swing boom with 5 ft. (1.5 m) telescoping capability or 8 ft. (2.4 m) swing boom with 3 ft. (0.9 m) telescoping capability.
Options
•ROPS/FOPS cab system
•fully enclosed canopy
•dust collector
•detergent system
•angle inclinator
•power pickup pot
•winch
•full enclosure
•dual boom controls
•linear rod changer
•carousel rod changer
Introduction iii
BI621947
iv Introduction
INTRODUCTION Standard Features and Options................................................................................................iii Table of Contents..................................................................................................................iv U.S./ Metric Conversions......................................................................................................viii Glossary of Terms..................................................................................................................x Component Locations ............................................................................................................ xii Optional Cab, Swing Arm, and Canopy...................................................................................xvi SAFETY SECTION 1 Hazard Classification............................................................................................................1-3 Safety Sign Symbols............................................................................................................ 1-4 Safety Information...............................................................................................................1-7 Safety Sign List (Machines without Enclosures)......................................................................1-9 Safety Sign Location (Machines without Enclosures)............................................................ 1-10 Safety Sign List (Machines with Enclosures)......................................................................... 1-13 Safety Sign Location (Machines with Enclosures)................................................................. 1-14 Safety Signs......................................................................................................................1-16 MAINFRAME/TRACKS SECTION 2 Track Oscillation Cylinders.................................................................................................... 2-2 Track Maintenance...............................................................................................................2-5 Track Tension Adjustment....................................................................................................2-7 Metric Bolt Torque Specifications..........................................................................................2-8 Track Assembly...................................................................................................................2-9 Separate Track Chain Assembly..........................................................................................2-9 Track Link - Repair & Replace............................................................................................. 2-10 Track Shoe (grouser) - Mounting to Track Chain.................................................................. 2-12 Grouser Bolt Torque (Direct Torque Method)...................................................................... 2-14 Grouser Bolt Torque (Torque Turn Method)........................................................................ 2-15 Track Chain & Shoe - Assembly & Installation..................................................................... 2-16 Crawler Carriage............................................................................................................... 2-18 Final Drive - General Description........................................................................................ 2-18 Final Drive - Removal from Track Frame............................................................................ 2-19 Final Drive - Installation into Track Frame........................................................................... 2-20 Final Drive Maintenance......................................................................................................2-21 Recommended Oils.......................................................................................................... 2-22 Final Drive Assembly..........................................................................................................2-24 Parking Brake - Description.............................................................................................. 2-25 Parking Brake - Removal & Installation............................................................................... 2-27 Towing Procedure - Gear Drive Disconnect........................................................................ 2-27 Idler Unit..................................................................................................................... 2-28 Track Rollers.....................................................................................................................2-35 Support Rollers..................................................................................................................2-40 BI621947
Table of Contents
Introduction v Table of Contents POWER TRAIN SECTION 3 Power Pack.........................................................................................................................3-2 Fuel System........................................................................................................................3-4 Engine Oil and Filter.............................................................................................................3-8 Engine Radiator.................................................................................................................3-10 Coolers .............................................................................................................................3-11 Changing Hydraulic Oil........................................................................................................3-14 HYDRAULIC/ELECTRICAL SYSTEMS SECTION 4 Tram Valve Components......................................................................................................4-2 Drill Control Circuit..............................................................................................................4-4 Drill Console Tram Circuit..................................................................................................... 4-6 Dual Boom Piping................................................................................................................4-7 Drill Console Assembly......................................................................................................... 4-8 Main Engine Harness...........................................................................................................4-9 Valve Tray Harness............................................................................................................4-10 Wiring Harnesses............................................................................................................... 4-11 Junction Box......................................................................................................................4-12 Drill Console Tram Control Wiring....................................................................................... 4-13 Shutdown Switch...............................................................................................................4-14 Joysticks........................................................................................................................... 4-15 Hydraulic Piping - Rexroth...................................................................................................4-17 Hydraulic Piping - Oilgear....................................................................................................4-18 Boom and Feed Piping....................................................................................................... 4-19 Hydraulic Piping - Swing Arm Machines................................................................................ 4-20 Boom and Feed Piping - Swing Arm Machines...................................................................... 4-21 AIR SYSTEM SECTION 5 Air Receiver Tank.................................................................................................................5-2 Air System Components.......................................................................................................5-7 Compressor Oil Piping.........................................................................................................5-9 Thermostatic Bypass Valve.................................................................................................5-9 Compressor Assembly - 300 CFM with Variable Displacement Motor.................................... 5-10 Drive Coupling................................................................................................................. 5-13 Drill String Grease System (optional)................................................................................... 5-14 Detergent System (optional)................................................................................................ 5-16 BI621947
vi Introduction
BOOM & FEED COMPONENTS SECTION 6 Boom Lift Cylinder...............................................................................................................6-2 Boom Swing Cylinderl..........................................................................................................6-4 Feed Dump Cylinder............................................................................................................. 6-6 Feed Swing Cylinder.............................................................................................................6-8 Feed Extension Cylinder.....................................................................................................6-10 Boom Shim/Wear Pads...................................................................................................... 6-12 Feed Table Pivot Pin........................................................................................................... 6-23 HPR4519/5123 Hydraulic Rock Drill Mounting..................................................................... 6-24 Mounting Slide Adjustment.................................................................................................. 6-25 HPR1H-ATW Hydraulic Rock Drill Mounting........................................................................... 6-26 Feed Chain Adjustment.......................................................................................................6-28 Hose Reel Timing............................................................................................................... 6-30 PRESSURE SETTINGS & ADJUSTMENTS SECTION 7 Engine Adjustments 7-3 Brake Valve Adjustments......................................................................................................7-4 Tram Valve Identification.......................................................................................................7-7 Tram Valve Adjustments.......................................................................................................7-8 Tram Valve/Joystick Adjustments........................................................................................ 7-10 Boom Joystick Adjustment................................................................................................. 7-12 Joystick Adjustments.........................................................................................................7-13 Main Pump Adjustments - Rexroth....................................................................................... 7-16 Auxiliary Pump Adjustments - Rexroth.................................................................................. 7-18 Main Pump Adjustments - Oilgear........................................................................................ 7-20 Auxiliary Pump Adjustments - Oilgear................................................................................... 7-22 Drill Valve Adjustments.......................................................................................................7-24 Compressor Speed and Motor Adjustment.......................................................................... 7-28 Compressor Drive Coupling................................................................................................ 7-30 Dust Collector Assembly.................................................................................................... 7-32 Centralizer......................................................................................................................... 7-45 Vertical Indicator................................................................................................................7-46 Drill Backpressure Valve.....................................................................................................7-48 VENDOR SERVICE INFORMATION SECTION 8 Index to Service Information.................................................................................................8-2 HYDRAULIC ROCK DRILL REPAIR SECTION 9 HPR4519/5123 Hydraulic Rock Drill Service Manual BI621947
Table of Contents
Introduction vii Table of Contents LUBRICATION AND TORQUE SPECIFICATIONS SECTION 10 Hydraulic Oils for Percussion Drills...................................................................................... 10-2 Lubrication and Inspection..................................................................................................10-3 Maintenance Schedule - Moderate Climate........................................................................... 10-4 Maintenance Schedule - Cold Climate................................................................................... 10-5 Recommended Engine Oils................................................................................................. 10-6 Preventative Maintenance................................................................................................... 10-7 Bolt Torque Specifications..................................................................................................10-8 Maintenance Record..........................................................................................................10-9 BI621947
U.S./ Metric Conversions
viii Introduction millimeter (mm) x 0.03937= inchx 25.4=mm centimeter (cm) 10mmx 0.3937= inchx 2.54=cm meter (m) 1000mmx 3.28= footx 0.305=m meter (m) x 1.09= yardx 0.914=m kilometer (km) 1000mx 0.62= milex 1.61=km AREA millimeter2 (mm 2)x0.00155= inch2 x645=mm 2 centimeter2 (cm2)x0.155= inch2 x6.45=cm 2 meter2 (m2) x10.8= foot2 x0.0929=m2 meter2 (m2) x1.2=yard2 x0.836=m2 hectare (ha) 1000m2 x2.47=acrex0.405=ha kilometer2 (km 2) x0.39= mile2 x2.59=km2 VOLUME centimeter3 (cm3)x0.061= inch3 x16.4=cm 3 liter x61= inch3 x0.016=L Milliliter (mL) 1cm3 x0.034= oz-liqx 29.6=mL liter (L) 1000mLx 1.06= quartx 0.946=L liter (L) x 0.26= gallonx 3.79=L meter3 (m 3) 1000Lx1.3= yard3 x0.76=m3 MASS gram (g)x 0.035= ouncex 28.3=g kilogram (kg) 1000gx 2.2=poundx 0.454=kg metric ton (t) 1000kgx1.1=ton (short)x 0.9078=t FORCE newton (N)x 0.225= poundx 4.45=N kilonewton (kN) x225 =poundx 0.00445=kN TORQUE newton meter (Nm)x8.9=lb inx 0.113=Nm newton meter (Nm)x 0.74=lb ftx1.36=Nm PRESSURE kilopascal (kPa) x4.0=in H2Ox0.249=kPa kilopascal (kPa)x 0.30=in Hgx3.38=kPa kilopascal (kPa)x 0.145=psix6.89=kPa barx14.5=psix0.06804=bar LENGTH
Multiply By To Get or Multiply By To Get BI621947
Introduction ix STRESS megapascal (MPa)x145=psix 0.00689=MPa POWER kilowatt (kW) x 1.34=hpx0.746=kW kilowatt (kW) x 0.948= Btu/sx 1.055=kW watt (W) x 0.74=ft lb/sx 1.36=W ENERGY kilojoule (kJ) x 0.948=Btux1.055=kJ joule (J) x 0.239= caloriex 4.19=J VELOCITY AND ACCELERATION meter per sec2 (m/s2)x3.28= ft/s 2 x0.305=m/s2 meter per sec (m/s)x 3.28= ft/sx 0.305=m/s kilometer per hour (km/h)x 0.62=mphx1.61= km/h TEMPERATURE Celsius (oC) = Fahrenheit (oF) - 32 ÷ 1.8Fahrenheit (oF) = Celsius (oC x 1.8) + 32 FLOW cubic feet/min. (cfm)x.4720= Liters/sec.x 2.1186=cfm gallons/min. (gpm)x .6308= Liters/sec.x 15.853=gpm
By To Get or Multiply By To Get BI621947
U.S./ Metric Conversions Multiply
Glossary of Terms
The following is a list of terms commonly used in the mining and construction industry. This list is not exhaustive, but pertains primarily to surface track drills as discussed in this manual.
Anti-Jam ........................A hydraulic system that senses a change in drill rotation and automatically retracts and extends drill steel to get through “bad ground” and prevent steel from getting stuck.
Belleville Washer ...........Another name for “Spring Washer”.
Bleed(ing) ......................A procedure to remove trapped air from a fluid.
Boom ............................Horizontal structure that supports and positions the feed. One end attaches to a pivot at the boom bulkhead at the front of the machine, the other end attaches to the positioner. Some booms are extendable, others are fixed (non-extendable).
Centralizer ....................A device used to keep the drill steel centered with respect to the centerline of the feed. An end centralizer is located at the bottom end of the feed. It has jaws that open and close around the drill steel, but allow the drill steel to pass through and rotate freely. The jaws are also used to clamp around the drill steel coupling and hold it tight for threading and unthreading of drill steel. A mid-point or travelling centralizer is used on long feeds to support the midpoint of the drill steel.
Collar(ing) ......................A term referring to starting a hole, whereby reduced hammer and feed pressure is used to get a hole started straight.
Detergent Tank..............A holding tank for water and detergent solution that is sometimes pressurized, or used in conjunction with a pump. It is part of a system used to suppress dust from the hole by means of injecting water into the hole while drilling is in progress. A detergent solution is mixed with water to act as a lubricant for the drill bit.
Drill Rod........................Another name for “drill steel”.
Drill Steel......................A specially made length of steel with threads on both ends to allow coupling together and to the drill shank and drill bit. The drill steel transfers energy from the drill to the bit and is also used to convey air or water for hole cleaning.
Drill Steel Coupling.........A devise used to join two pieces of drill steel together and to join the drill steel to the drill shank, by means of internal female threads or sometimes male and female threads.
Drill String.....................Refers to multiple pieces of drill steel joined together.
Dump............................Term used to describe the position of the feed relative to the centerline of the boom. Dump UP tilts top of feed towards boom, dump DOWN tilts top of feed away from boom.
Dust Collector...............A device used to collect dust and cuttings from the hole by means of vacuum, while drilling is in progress.
Extend ..........................To move object OUT or AWAY from machine in the horizontal plane, or to move object TOWARD the ground in the vertical plane.
x Introduction
BI621947
Feed .............................Structure used to support the rock drill, drill steel and rod changer. The rock drill moves up and down the feed by means of a chain drive system, or in some cases a cable or hydraulic cylinder drive system. Feeds come in various lengths, depending on length of drill steel required.
Feed Mounting...............Another name for “Feed Table”
Feed Table ....................A device that attaches to the positioner by means of a pin and hydraulic cylinder, and is used to support the feed.
Hammer(ing) ..................A term used to describe the action of the drill hammer or piston striking the drill shank, thus transferring the blow energy through the drill steel to the bit.
Oscillation .....................Refers to the up and down movement of the tracks. During tramming the track oscillation cylinders are unlocked to allow the tracks to move up and down according to the terrain. During drilling the track oscillation cylinders are locked, to prevent the tracks from moving.
Pickup Pot.....................A device that can be hydraulically raised or lowered over the hole and provides a means of attaching the dust collector hose to remove dust and cuttings from the hole.
Positioner ......................A device attached to the end of the boom, that allows the feed to pivot and be positioned at various angles.
Pre-Cleaner ...................A device used in conjunction with the dust collector, that removes large particles before they reach the dust collector.
Rattle ............................A term used to describe loosening the drill string joints by “hammering” the drill steel, by using short bursts of the hammer with no feed pressure on the drill bit.
Retract .........................To move object IN or TOWARDS the machine in the horizontal plane, or to move object AWAY from the ground in the vertical plane.
Rock Drill.......................The device that provides the percussive and rotation forces for drilling. Sometimes referred to as the “hammer” or “drifter”.
Shank ............................A specially made short length of steel with splines at one end and threads at the other end. The splined end is inserted into the rock drill and engages the splines of the chuck end of the drill. The drill steel attaches to the other end by means of a coupling.
Spring Washer...............A cup shaped washer that, when compressed provides a “spring like” action. Also called "belleville washer".
Sting .............................To apply pressure to the ground by extending the feed to prevent the feed from moving while drilling.
Stinger ..........................A device attached to the end of the feed which contacts the ground to stabilize the feed while drilling.
Swing ............................Term used to indicate movement of a component to right or left, relative to machine as viewed from rear.
Tram.............................To move and steer the machine from the tram station or operator’s cab.
Introduction xi
Glossary of
BI621947
Terms
• 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.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
