Technical Manual
© Bucyrus All Rights Reserved
R
BI620442
BUCYRUS
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Service Manual Series SKSS Infinity Blasthole Drill Reedrill 3501 S. FM Hwy 1417, Denison, TX 75020P.O. Box 998, Sherman, TX 75091-0998 Telephone 1-800-854-9030Telefax 1-800-582-6570 for Serial No. 1N67Y54 BI620442
Parts Ordering & Product Support
Use only genuine Reedrill parts in the maintenance, rebuild, or repair, of Reedrill machines. Reedrill shall have no liability as to any unauthorized modification of machines or parts and shall have no obligation or liability as to any machines or parts which have been improperly handled, or which have not been operated, maintained, or repaired according to Reedrill's furnished manuals, or other written instructions, or which are operated with other than genuine Reedrill parts.
Your cooperation in furnishing as much information as possible will assist us in filling your orders correctly and in the shortest possible time.
1.IDENTIFICATION OF THE MACHINE
Always furnish the Reedrill Model Number and Serial Number when ordering parts. This information is found on the machine nameplate.
2.PART NUMBER AND DESCRIPTION
In addition to the 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.
3.SHIPMENT
Unless otherwise instructed, all shipments will be made via road freight and charged on our invoice. Shipments cannot be made on open account until your credit has been approved by our Accounting Department.
MAILING ADDRESS
Reedrill WA
P. O. Box 1006
Kelmscott WA, 6111
FOR PARTS ORDER ENTRY
Reedrill WA
Telephone (08) 9495 7700
Fax (08) 9495 7750
Australian Branches
SHIPPING ADDRESS
Reedrill WA
Lot 21 Brant Rd
Kelmscott WA, 6111
Brisbane 24 Lavarack Ave
Eagle Farm QLD 4009
Ph. (07) 3868 2144
Fax. (07) 3868 2105
Newcastle
139 Racecourse Rd
Rutherford NSW 2320
Ph. (02) 4932 0000
Fax (02) 4932 0733
Mackay 10-12 Corporate Dve
Mackay QLD 4740
Ph. (07) 4953 5600
Fax (07) 4952 5311
SKSS Introduction i
BI620442
Safety Information
This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury or property damage.
WARNING:
BEFORE STARTING ENGINE:
*Study Operator and Service Manuals
*Practice All Safety Precautions
*Make Pre-Operation Check
*Learn Controls Before Operating
It is YOUR responsibility to understand and follow manufacturer's instructions on machine operation and service, and to observe pertinent safety precautions, laws and regulations.
Failure to read and understand this manual and all safety, capacity and instruction placards on the machine before operating the unit, constitutes a misuse of the machine. It is your responsibility to know the manufacturer's specific requirements, government regulations, required precautions and any work hazards which may exist. You must make these known to all personnel working with the equipment or in the area, so that all may take the necessary and required safety precautions. Keep all children, visitors, and untrained personnel away from the equipment. It is also your responsibility to operate your equipment with skill, good judgment, and caution. Following recognized safety procedures will help you avoid accidents. Failure to heed these instructions can result in property damage, serious injury or death.
Drill Model :__________________________________________
Drill Serial No:________________________________________
Date Drill Delivered :___________________________________
Dealer :_____________________________________________
Customer :___________________________________________
ii SKSS Introduction
BI620442
Product Description
WARNING:
DO NOT use this machine for any other purpose than blasthole drilling.
Rotary blasthole drills are designed for blasthole drilling purposes only.
Any other use could result in personal injury, property damage and will void the warranty.
The Reedrill Infinity Series is specifically designed for Blast Hole Drilling Operations.
The Infinity Series SKSS is a crawler mounted drill rig, which consist of two (2) major assemblies:
1.Rotary Drill Assembly
2.Excavator Type Undercarriage
The Rotary Drill assembly is made up of the Engine Package, Compressor Package, Hydraulic System, Rotary Drive, Pull-Down and Hoisting System and Drill Pipe Handling mechanism.
The Crawlers are powered by two (2) hydrostatic motors. Each Crawler has its own independent, variable and reversible speed control, and is equipped with 29.5 inch (750mm) wide triple grouser shoes.
Manual Contents
This manual is furnished with your Reedrill Infinity Series Blasthole Drill to aid you in performing the necessary service work to maintain your blasthole drill in good running condition.
CAUTION:
Each person performing service work must be satisfied that they have adequate knowledge and training to perform the required tasks. A thorough understanding of hydraulic and pneumatic systems as well as electrical and mechanical knowledge and experience is required.
This manual contains repair and adjustment information for all major operating systems on the machine. In some cases such as hydraulic pumps and motors it is better to replace the unit with a new or rebuilt unit than to perform major repairs.
Should further information be desired or should particular problems arise which are not covered sufficiently in this manual, the matter should be referred to Reedrill
The descriptions and specifications contained in this manual were in effect at the time of printing. The right is reserved to make changes at any time without notice and without obligation.
SKSS Introduction iii
BI620442
iv SKSS Introduction
Introduction ............................................................................................................................ Parts Ordering & Product Support....................................................................................................i Safety Information ...............ii Product Description........................................................................................................................iii Manual Contents .............iii Table of Contents............................................................................................................................iv General Locator........................................................................................................................... .xiv Section 1 Safety.................................................................................................................................1-2 Safety locator...............................................................................................................................1-8 Section 2 Operator's Controls and Indicators.................................................................................2-2 Control Panels.............................................................................................................................2-2 Right Hand Control Panel.................................................................................................2-3 Circuit Breakers...........................................................................................................................2-4 Light Switches..............................................................................................................................2-5 Instrument Panel..........................................................................................................................2-5 Instrument Panel and Circuit Breakers........................................................................... 2-5 System Pressure Gauge Panel........................................................................................2-6 Left Hand Control Panel...................................................................................................2-8 Air Conditioner ................................................................................................................ 2-15 Introduction ................................................................................................................................. 2-19 Unit Specification 2-20 Technical Data and Control Settings..........................................................................................2-24 Installation and Commissioning................................................................................................. 2-26 Operating Instructions......................................................................................................... 2-36 Routine Maintenance Procedures..............................................................................................2-39 Fault Diagnosis.......................................................................................................................... 2-47 Warranty..................................................................................................................................... 2-58 Basic Spare Parts Listing...........................................................................................................2-59 Reference Drawings..................................................................................................................2-62 Condenser 2-67 Evaporator 2-68 Compressor ............................................................................................................................... 2-71 Section 3 Main Frame Repair ............................................................................................................3-2 Welding Manual ............................................................................................................................3-2 Leveling Jacks ................................................................................................................. 3-38 Remove-Replace 3-39 Mast Elevating Cylinders................................................................................................3-40 BI620442
Table of Contents
SKSS Introduction v
Remove-Replace 3-42 Crawler Assembly ...........................................................................................................3-44 Crawler Component Repair....................................................................................................... 3-45 Metric Bolt Torque Specifications ..................................................................................3-46 Track Maintenance ..........................................................................................................3-47 Before Operating the Machine:...................................................................................................3-47 General Maintenance .....3-47 Track Tension Adjustment..............................................................................................3-48 Description ................................................................................................................................. 3-50 Nitrogen Tensioner 3-51 Hydraulic Tensioner.................................................................................................................... 3-52 Nitrogen Tensioner Assemby......................................................................................................3-53 Nitrogen Tensioner - Filling Instructions...................................................................................... 3-54 Nitrogen Tensioner - Pressure Check ........................................................................................ 3-56 Nitrogen Tensioner - Pressure Release..................................................................................... 3-56 Track Chain - Separate ....................................................................................................3-58 Track Chain Repair..........................................................................................................3-60 Track Link - Repair and Replace................................................................................................ 3-60 Track Link - Description....................................................................................................... 3-61 Track Shoes Installation.................................................................................................3-62 Track Link Position............................................................................................................ 3-62 Track Shoe - Mounting to Track Chain ....................................................................................... 3-62 Track Shoe Bolt Torque (Direct Torque Method)..........................................................3-64 Track Shoe Bolt Torque (Torque Turn Method)............................................................3-65 Track Chain and Shoe Installation.................................................................................3-66 Track Chain with Shoes.............................................................................................................3-66 Track Chain & Shoe - Assembly & Installation........................................................................... 3-66 Final Drive........................................................................................................................3-68 Final Drive - General Description...............................................................................................3-68 Final Drive Unit Removal................................................................................................3-69 Removal from Track Frame....................................................................................................... 3-69 Installation into Track Frame......................................................................................................3-70 Final Drive Maitenance ....................................................................................................3-71 Oil Check / Change............................................................................................................. 3-71 Final Drive Oil...................................................................................................................3-72 Specifications ............................................................................................................................. 3-72 Recommended Oil.....................................................................................................................3-72 Final drive Assembly .......................................................................................................3-74 Parking Brake - Description.......................................................................................................3-75 Final Drive Disconnect ....................................................................................................3-76 Final Drive - Disconnect & Parking Brake .....................................................................3-77 Towing Procedure - Gear Drive Disconnect............................................................................... 3-77 Parking Brake - Removal & Installation......................................................................................3-77 Idler Assembly ................................................................................................................. 3-78 Idler Unit Removal ...........................................................................................................3-80 Idler Unit Assembly .........................................................................................................3-82 Track and Support Rollers..............................................................................................3-86 BI620442
Table of Contents
vi SKSS Introduction
General Description............................................................................................................ 3-86 Track Roller - Removal & Disassembly..................................................................................... 3-88 Support Roller - Removal & Disassembly................................................................................. 3-89 Track and Support Roller - Assembly.........................................................................................3-90 Track and Support Roller - Test and Install.................................................................................3-91 Auxiliary Crane ................................................................................................................ 3-93 Section 4 Power Group Locator .......................................................................................................4-2 Engine ................................................................................................................................4-3 Engine Oil Reserve System.........................................................................................................4-3 Engine Oil Reserve System Circuit.............................................................................................4-3 Wiring Diagram - Oil Reserve Basic Circuit................................................................................4-4 Oil Reserve Systems...................................................................................................................4-5 LED Monitor Readings.................................................................................................................4-6 Adjustment of Running Oil Level..................................................................................................4-6 Oil Reserves................................................................................................................................4-7 Troubleshooting ............................................................................................................................4-7 Oil Reserves Systems - Maintenance..........................................................................................4-8 Engine and Air Cleaners................................................................................................... 4-9 Engine and Compressor Air Cleaner Service............................................................................ 4-10 Flexible Drive Coupling ..................................................................................................4-13 Flexible Drive Coupling Service..................................................................................................4-13 Removal..................................................................................................................................... 4-14 Installation ...4-14 Pump Drive..................................................................................................................... 4-16 Pump Drive Assembly - Removal and Replacement................................................................. 4-16 Pump Identification 4-17 Pump Drive Gearbox .......................................................................................................4-18 Pump Drive Gearbox - Repair.................................................................................................... 4-19 Disassembly: .............................................................................................................................4-19 Inspection and Repair:......................................................................................................... 4-19 Assembly: 4-19 Disassembly ..............................................................................................................................4-21 Installation of Pump Drive Gearbox:...........................................................................................4-21 Lubrication: ................................................................................................................................. 4-21 Hydraulic Piston Pumps .................................................................................................4-22 Hydraulic Piston Pumps - Removal and Replacement 4-22 Tram and Rotation Pump................................................................................................4-23 Application and Service Manual..................................................................................................4-23 Hydraulic Piston Pumps .................................................................................................4-52 Hydraulic Piston Pumps - Removal and Replacement 4-52 Feed and Auxiliary Pump................................................................................................4-53 Repair Manual 4-53 Hydraulic Gear Pumps ....................................................................................................4-84 Hydraulic Gear Pumps - Removal and Replacement ................................................................ 4-84 BI620442
Table of Contents
SKSS Introduction vii
Service Manual 4-85 Compressor Drive Coupling ..........................................................................................4-98 Compressor Drive Coupling - Removal and Replacement 4-99 Compressor Installation ...............................................................................................4-100 Compressed Air Functions......................................................................................................4-101 Before Installation: 4-101 Compressor Unit - Installation:.................................................................................................4-101 Before Start-Up of New or Rebuilt Compressor: 4-101 Main and Auxiliary Air....................................................................................................4-102 Functional Description.............................................................................................................4-102 Compressed Air Subsystem Components.............................................................................. 4-102 Compressor Circuit .......................................................................................................4-103 Compressor Air End ......................................................................................................4-104 Compressor Shaft Seal .................................................................................................4-105 Compressor Shaft Seal Replacement..................................................................................... 4-105 Compressor Discharge Check Valve...........................................................................4-108 Compressor Receiver Tank Assembly ........................................................................4-109 Separator Elements..................................................................................................................4-110 Separator Elements - Remove & Replace................................................................................4-112 Minimum Pressure Valve ..............................................................................................4-113 Minimum Pressure/Check Valve Maintenance..........................................................................4-113 Thermal By-pass valve .................................................................................................4-114 Thermal By-pass Valve Maintenance........................................................................................4-115 Compressor Oil Filter ....................................................................................................4-116 Routine Maintenance .................................................................................................................4-118 Changing Filter Elements..........................................................................................................4-118 Bearing Oil Filter ............................................................................................................4-119 Bearing Oil Filter Element Replacement...................................................................................4-119 Oil Stop Valve -............................................................................................................... 4-120 Oil Stop Valve Maintenance ......................................................................................................4-121 Compressor Inlet Valve.................................................................................................4-122 Control System................................................................................................................. 4-122 Sullicon Control........................................................................................................................ 4-122 Butterfly Inlet Valve 4-122 Compressor Inlet Valve Control...................................................................................4-123 System Regulator ..........................................................................................................4-124 Relieving Regulators ................................................................................................................ 4-124 System Pressure Regulator Maintenance............................................................................... 4-125 Blowdown Valves..........................................................................................................4-126 Running Blowdown Valve......................................................................................................... 4-126 Running Blowdown Valve Maintenance .................................................................................... 4-126 System Blowdown Valve.......................................................................................................... 4-127 System Blowdown Valve Maintenance..................................................................................... 4-127 Compressor discharge Temperature gauge and Senders....................................................... 4-128 Compressor Oil Cooler Assembly ................................................................................4-129 Radiator/Hydraulic Oil Cooler Assembly .....................................................................4-130 Radiator/Oil Cooler Assembly ......................................................................................4-131 BI620442
Table of Contents
viii SKSS Introduction
Aluminium Tube Oil Coolers.........................................................................................4-132 Service Manual ......................................................................................................................... 4-132 Copper Tube Oil Coolers..............................................................................................4-140 Service Manual 4-140 Radiator and Core Assembly ........................................................................................4-148 Service Manual ......................................................................................................................... 4-148 Section 5 Dust Control Systems .......................................................................................................5-2 Water Injection ...................................................................................................................5-3 Water Injection Control.................................................................................................................5-5 Basic Water Injection System Circuit........................................................................................... 5-7 Water Pump........................................................................................................................5-8 Servicing Instructions...................................................................................................................5-9 General Care of the Pump...........................................................................................................5-9 Servicing the Plunger Packings...................................................................................................5-9 Reassembling Plunger Packings...............................................................................................5-11 Servicing the Pump Valves........................................................................................................5-12 Pump Specifications............................................................................................................ 5-14 Torque Requirements.................................................................................................................5-14 Reassembling Valve Parts.........................................................................................................5-14 Servicing the Crankshaft............................................................................................................5-14 Servicing the Crossheads..........................................................................................................5-16 Recommended Lubricants........................................................................................................5-17 Water Pump Motor Repair.........................................................................................................5-17 Water Pump Drive Coupling.......................................................................................................5-17 Water Pump Motor...........................................................................................................5-18 Service Manual 5-18 High Pressure Cleaner ....................................................................................................5-26 Section 6 Mast Weldment 6-2 Mast Repair..................................................................................................................................6-2 Mast Assembly.............................................................................................................................6-3 Mast Pivot ................6-4 Feed Cylinders ..................................................................................................................6-5 Feed Cylinder - Removal.............................................................................................................6-8 Feed Cylinder Assembly ...............................................................................................6-10 Installation ..................................................................................................................................6-11 Hoist/Pulldown Cable Adjustment .................................................................................6-12 Hoist/Pulldown Cable Replacement ..............................................................................6-15 Rotary Head Guide Alignment........................................................................................6-18 Rotary Drive Assembly ...................................................................................................6-20 Rotary Drive - Removal from Mast.............................................................................................6-20 BI620442
Table of Contents
SKSS Introduction ix
Rotary Drive - Installation.................................................................................................... 6-20 Rotary Drive Gearbox .....................................................................................................6-21 Rotary Drive Gearbox - Repair...................................................................................................6-23 Main Shaft Bearing Preload........................................................................................................6-23 Winch Assembly ..............................................................................................................6-24 Precautions on the Use of Winches 6-24 Wire Rope.................................................................................................................................. 6-24 Winch Assembly Service Manual...............................................................................................6-31 Deck Wrench ...................................................................................................................6-60 HOBO Wrench.................................................................................................................6-61 Breakout System - HOBO......................................................................................................... 6-62 Pipe Positioner................................................................................................................ 6-63 Carousel Pipe Rack .........................................................................................................6-64 Major Components............................................................................................................... 6-64 Rod Handling-Carousel Indexing ................................................................................................6-65 Pipe Rack Bearings - Removal..................................................................................................6-67 Pipe Rack Components - Inspection 6-70 Pipe Rack - Assembly and Installation.......................................................................................6-71 Pipe Rack Roller - Remove and Replace.................................................................................. 6-72 Pipe Rack Roller - Disassembly and Assembly......................................................................... 6-73 Section 7 Hydraulic Symbols ............................................................................................................7-2 Pressure Setting Sequence ..............................................................................................7-4 Hydraulic Tank...................................................................................................................7-6 Main Return and Case Drain Filter ...................................................................................7-9 Routine Maintenance 7-10 Changing Filter Elements...........................................................................................................7-10 Main Hydraulic Pumps ....................................................................................................7-12 Pump Identification 7-12 Right Track Left Track/Rotation Pumps.........................................................................7-13 AA4VG 180 Hydraulic Pump HD/D Control ................................................................................ 7-14 Port Locations................................................................................................................. 7-16 Setting Procedure.............................................................................................................. 7-17 Mechanical Zero Position - HD Pump Control............................................................................ 7-18 Hydraulic Zero Position - HD Pump Control...............................................................................7-19 Charge Pressure, High Pressure and P.O.R. Relief Settings 7-20 Set Charge Pressure.................................................................................................................7-21 Set Crossover Relief........................................................................................................... 7-21 Set Pressure Override (P.O.R.)................................................................................................. 7-23 Charge Filter ....................................................................................................................7-24 Routine Maintenance 7-25 Changing Filter Elements...........................................................................................................7-25 Tram/Rotation Pump Circuit..........................................................................................7=27 Tram/Rotation Pump Circuit.......................................................................................................7-28 Rotation Circuit............................................................................................................... 7-29 BI620442
Table of Contents
Table of Contents
x SKSS Introduction
Rotation/Tram Motor Circuit.......................................................................................................7-30 Loop Filters......................................................................................................................7-31 Routine Maintenance 7-31 Changing Filter Elements...........................................................................................................7-34 Rotary Drive Gearbox Motor...........................................................................................7-35 Rotary Drive Gearbox Motor - Repair.........................................................................................7-35 Case leakage By-pass test........................................................................................................7-35 Shaft Seal Replacement............................................................................................................7-35 Trouble Shooting 7-38 Feed and Auxiliary Pump................................................................................................7-40 Feed & Auxiliary Functions Pump..............................................................................................7-41 Function of Load Sensing Control (DRS) 7-41 Adjustment Procedure...............................................................................................................7-41 Auxiliary and Feed circuits.........................................................................................................7-42 Main Control Valves........................................................................................................7-43 Valve Stand Assembly................................................................................................................7-43 MP18 Valve-Jack and Mast Raise Valve .........................................................................7-44 MP22 Valve-Hoist and Pulldown Control.......................................................................7-46 4WE6-Aux Function and Mast Valve..............................................................................7-49 Counterbalance Valve .....................................................................................................7-53 Counterbalance Valve Adjustments............................................................................................7-53 Pilot Control Manifold .....................................................................................................7-54 Control Valve Assembly ..................................................................................................7-56 Individual Valves (V03 - V22)......................................................................................................7-56 Hydraulic Feed Circuit ....................................................................................................7-64 Feed Valve Assembly ......................................................................................................7-72 Jack Control and Mast Elevating Circuit .......................................................................7-74 Pressure Adjustment 7-75 Leveling Jack Cylinders .................................................................................................7-76 Counterbalance Valve Test Procedure ....................................................................................... 7-77 Mast Elevating Cylinders................................................................................................7-78 Counterbalance Valve Test Procedure 7-79 Auxiliary Functions Circuit .............................................................................................7-80 Hydraulic Operated Breakout Wrench...........................................................................7-82 Setting of Sequence Valves.......................................................................................................7-83 Cooler Fan Circuit ...........................................................................................................7-84 Fan Motor Circuit.............................................................................................................. 7-84 Adjustment 7-84 Cooler Fan Motor .............................................................................................................7-86 Basic Cooler Circuit ........................................................................................................7-87 Cooler Fan Motor Assembly ...........................................................................................7-88 Cooler Fan Motor Shaft Seal Change 7-89 Hydraulic Thermostatic Valve........................................................................................7-92 Central Lube ....................................................................................................................7-93 Hydraulic Circuit......................................................................................................................... 7-94 Air Conditioner Compressor Drive Circuit....................................................................7-95 Air Conditioner Drive Motor............................................................................................7-96 BI620442
SKSS Introduction xi Shaft Seal Replacement............................................................................................................7-98 Water Injection Circuit ...................................................................................................7-100 Water Injection Valve.......................................................................................................... 7-101 Toc-2 Controller............................................................................................................... 7-102 Water Injection Valve..................................................................................................... 7-103 Service Manual 7-103 Hydraulic Cylinder Repair ............................................................................................7-120 Hydraulic Cylinders Type Chart................................................................................................7-120 Hydraulic Cylinder Overhaul Information.................................................................................. 7-121
8 Electrical Locator ..............................................................................................................8-2 Jump Starting....................................................................................................................8-6 Precautions ..................................................................................................................................8-7 Procedure: ...................................................................................................................................8-7 Batteries .............................................................................................................................8-8 Welding Precautions .........................................................................................................8-9 Vigilante Guide ................................................................................................................ 8-10 Vigilante Guide Contents .....8-10 Electrical Vendor Information.........................................................................................8-29 Head Speed Module ...................................................................................................................8-29 Inclinometer 8-31 Ladder Proximity Switch............................................................................................................8-35 Laser .......................................................................................................................................... 8-36 Level Switches................................................................................................................. 8-38 Level Transducers.............................................................................................................. 8-43 Pressure Transducers ...............................................................................................................8-54 Temperature Transducer............................................................................................................8-64 Water Flow Transducer..............................................................................................................8-74 Water Control Module................................................................................................................. 8-89 Rod Counter Proximity Switch................................................................................................... 8-98 Remote Fuel Level Display........................................................................................................8-99 Section 9 Central Lube System .........................................................................................................9-2 Hydraulic Control Schematic........................................................................................................9-3 Central Lube System Circuit Drawing............................................................................. 9-5 Central Lube and Bit Lube Tank Assembly .....................................................................9-6 Central Lube System .........................................................................................................9-9 Central Lube Pump Module..........................................................................................................9-9 Central Lube Pump.............................................................................................................. 9-27 Vent Valve ...................................................................................................................................9-50 SL-1 Injector Assembly..............................................................................................................9-52 Central Lube and Bit Lube Tank Assembly ...................................................................9-54 Bit Lube Circuit................................................................................................................9-56 Table of Contents BI620442
Section
• 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
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