Issuu

Technical Manual

BI620428

BUCYRUS

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Service Manual for Serial No's. 1H67C05 1H67C43 Series SKSS-15 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 BI620428

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.

SKSS Introduction i

MAILING ADDRESS FOR PARTS ORDER ENTRY SHIPPING ADDRESS Reedrill WAReedrill WAReedrill WA P. O. Box 1006Telephone (08) 9495 7700Lot 21 Brant Rd Kelmscott WA, 6111Fax (08) 9495 7750Kelmscott WA, 6111 Australian Branches Brisbane Newcastle Mackay 24 Lavarack Ave139 Racecourse Rd10-12 Corporate Dve Eagle Farm QLD 4009Rutherford NSW 2320Mackay QLD 4740 Ph. (07) 3868 2144Ph. (02) 4932 0000Ph. (07) 4953 5600 Fax. (07) 3868 2105Fax (02) 4932 0733Fax (07) 4952 5311 BI620428

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

BI620428

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

BI620428

iv SKSS Introduction

Introduction Parts Ordering & Product Support ......................................................................................i Safety Information ................................................................................................................ii Product Description ............................................................................................................ iii Manual Contents ..................................................................................................................iii Table of Contents .................................................................................................................iv General Locators ............................................................................................................... xvi Section 1 Safety.................................................................................................1-1 Personal Protective Equipment 1-2 Noise ..........................................................................................................................................1-2 Electrical Contact: ..........1-2 Overhead and Buried Utilities ...1-2 Contact With Electric Wires.......................................................................................................1-3 Contaminated Air ........................................................................................................................1-3 Machine Stability ...........1-4 Moving and Rotating Parts .........................................................................................................1-5 High Pressure Air or Fluid .....1-5 Before Operation............................................................................................................................1-5 During Operation .........1-6 Maintenance 1-8 Safety Locators ..................................................................................................................1-9 Section 2 Operator’s Cab/ Controls ............................................................... 2-1 Operator’s Controls and Indicators .................................................................................2-2 Control Panels ...........................................................................................................................2-2 Right Hand Control Panel.................................................................................................2-3 Instrument Panel and Circuit Breakers ...........................................................................2-4 Circuit Breakers ..........2-4 Light Switches ...........2-5 Instrument Panel .........2-5 System Pressure Guage Panel.........................................................................................2-6 Left Hand Control Panel....................................................................................................2-8 Foot Control Pedals ........................................................................................................2-14 Thread Grease Switch ........................................................................................................14 Pipe Safety Arm Override Switch ......................................................................................14 Foot Control Pedals ...........................................................................................................14 Air Conditioner ....................................................................................................................15 Contents ................................................................................................................................. 2-17 Introduction ............................................................................................................................... 2-19 Unit Specification 2-20 Technical Data and Control Settings 2-23 Installation and Commissioning ...............................................................................................2-25 BI620428

Table of Contents

SKSS Introduction v Table of Contents Operating Instructions ..............................................................................................................2-32 Routine Maintenance Proceedures 2-34 Fault Diagnosis ........2-38 Warranty................................................................................................................................... 2-48 Basic Spare Parts Listing ...2-49 Reference Drawings ...2-51 Section 3 Main Frame - Crawlers .................................................................... 3-1 Main Frame Repair ............................................................................................................3-2 Leveling Jacks ...................................................................................................................3-3 Leveling Jack Cylinders 3-4 Remove .....................................................................................................................................3-4 Repair........................................................................................................................................3-4 Replace......................................................................................................................................3-4 Mast Elevating Cylinders ..................................................................................................3-5 Remove .....................................................................................................................................3-7 Repair........................................................................................................................................3-7 Replace......................................................................................................................................3-7 Crawler Assembly ..............................................................................................................3-8 Crawler Component Repair....................................................................................................... 3-9 Metric Bolt Torque Specifications ..................................................................................3-10 Track Maintenance...........................................................................................................3-11 Before Operating Machine: .3-11 General Maintenance ................................................................................................................3-11 Track Tension Adjustment ..............................................................................................3-12 Hydraulic Tensioner ......3-13 Correct Track Tension ..............................................................................................................3-13 Description 3-14 Nitrogen Tensioner ......3-15 Hydraulic Tensioner ........................................................................................................3-16 Repair...................................................................................................................................... 3-16 Nitrogen Tensioner Assembly ........................................................................................3-17 Track Tension Adjustment ..............................................................................................3-18 Nitrogen Tensioner - Filling Instructions ....................................................................................3-18 Nitrogen Tensioner - Pressure Check ...................................................................................... 3-20 Nitrogen Tensioner - Pressure Release 3-20 Track Chain - Separate....................................................................................................3-22 Track Chain Repair..........................................................................................................3-24 Track Link - Repair & Replace .................................................................................................3-24 Track Link - Description ...........................................................................................................3-25 Track Shoes Installation..................................................................................................3-26 Track Link Position .......3-26 Track Shoe - Mounting to Track Chain .....................................................................................3-26 Track Shoe - Mounting to Track Chain .....3-27 Direct Torque Method ....3-27 BI620428

vi SKSS Introduction

Torque Turn Method .....3-27 Track Shoe - Retightening ..3-27 Track Shoe Bolt Torque (Direct Torque Method) ..........................................................3-28 Track Shoe Bolt Torque (Torque Turn Method) ............................................................3-29 Track Chain and Shoe Installation.................................................................................3-30 Track Chain with Shoes ..3-30 Track Chain & Shoe - Assembly & Installation 3-30 Final Drive .........................................................................................................................3-32 Final Drive - General Description .............................................................................................3-32 Final Drive Unit Removal................................................................................................. 3-33 Removal from Track Frame .....................................................................................................3-33 Installation into Track Frame ....................................................................................................3-34 Final Drive Maintenance ..................................................................................................3-35 Oil Check / Change .....3-35 Final Drive Oil...................................................................................................................3-36 Specifications ........................................................................................................................... 3-36 Recommended Oil ...3-36 Final Drive Assembly .......................................................................................................3-37 Parking Brake - Description .3-38 Final Drive Disconnect ....................................................................................................3-39 Final Drive - Disconnect & Parking Brake .....................................................................3-40 Towing Procedure - Gear Drive Disconnect 3-40 Parking Brake - Removal & Installation 3-40 Idler Assembly ..................................................................................................................3-41 Idler Unit Removal ...........................................................................................................3-43 Idler Unit - Assembly ........................................................................................................3-45 Track and Support Rollers ..............................................................................................3-49 General Description .....3-49 Track Roller - Removal & Disassembly 3-51 Support Roller - Removal & Disassembly ............................................................................... 3-52 Track and Support Roller - Assembly 3-53 Track and Support Roller - Test and Install............................................................................... 3-54 Auxiliary Crane .................................................................................................................3-56 Palfinger Hydraulic Crane Operators Manual .................................................................... 3-57 Contents 3-58 Before Operation of Crane .......................................................................................................3-64 Start Operation of Crane ...3-65 Section 4 Engine / Drive Train / Compressor ................................................ 4-1 Power Group Locator ........................................................................................................4-2 Engine .................................................................................................................................4-3 Engine Fuel System ......4-4 Engine Oil Reserve System Circuit ......................................................................................... 4-12 Engine Oil Reserve System .....................................................................................................4-12 Oil Reserve Systems ...4-14 LED Monitor Readings .............................................................................................................4-15 BI620428

Table of Contents

SKSS Introduction vii Table of Contents Signals..................................................................................................................................... 4-15 Adjustment of Running Oil Level ..............................................................................................4-15 Servicing.................................................................................................................................. 4-16 Troubleshooting ........4-16 Oil Reserves Systems - Maintenance...................................................................................... 4-17 Engine and Compressor Air Cleaners ...........................................................................4-18 Engine and Compressor Air Cleaner Service .................................................................... 4-19 Inspection and General Service ...............................................................................................4-19 Engine and Compressor Air Cleaner Service .......................................................................... 4-21 Safety Element Service ...4-21 Flexible Drive Coupling Service.....................................................................................4-22 Adaptor Flanges .......4-22 Centering Flanges ....................................................................................................................4-22 Rubber Element ......4-22 Tube Assembly .........................................................................................................................4-22 Mounting Screws and Adhesive 4-23 Pump Drive Assembly - Removal and Replacement 4-25 Pump Drive .......................................................................................................................4-25 Pump Identification ...................................................................................................................4-26 Pump Drive Gearbox .......................................................................................................4-27 Pump Drive Gearbox - Repair ..................................................................................................4-28 3" Input Shaft Assembly ...4-30 Hydraulic Piston Pumps .................................................................................................4-31 Hydraulic Piston Pumps - Removal and Replacement 4-31 Hydraulic Piston Pumps - Repair ...........................................................................................4-31 Tram and Rotation Pumps..............................................................................................4-32 Hydraulic Piston Pumps .................................................................................................4-69 Hydraulic Piston Pumps - Removal and Replacement ............................................................ 4-69 Hydraulic Piston Pumps - Repair ...........................................................................................4-69 Feed and Auxiliary Pump................................................................................................4-70 Hydraulic Gear Pumps ..................................................................................................4-101 Hydraulic Gear Pumps - Removal and Replacement .............................................................4-101 Hydraulic Gear Pumps - Repair 4-101 Compressor Installation ................................................................................................4-115 Compressor Replacement and Drive Coupling Maintenance 4-116 Disassembly ...........................................................................................................................4-116 Before Installation of New or Rebuilt Compressor: .................................................................4-117 Reassembly ............................................................................................................................4-118 Before Start-Up of New or Rebuilt Compressor: .....................................................................4-118 Drill Compressor ............................................................................................................4-119 High Pressure Compressor ..........................................................................................4-120 Section 1 Safety 4-120 General ...................................................................................................................................4-120 Pressure Release ....4-120 Fire and Explosion 4-121 Moving Parts 4-121 Toxic and Irritating Substances ...............................................................................................4-121 Electrical Shock ...................................................................................................................... 4-122 BI620428

viii SKSS Introduction

Lifting ....................................................................................................................................... 4-122 Section 2 Description ...........................................................................................................4-123 Introduction 4-123 Compressed Air Functions .....................................................................................................4-123 Sullair Compressor Unit ..4-124 Compressor Discharge System 4-125 Compressor Cooling and Lubrication System 4-126 Compressor Fluid Circuit ..............................................................................................4-127 Compressor Condensation Table................................................................................ 4-130 Compressor Air Circuit 1475cfm @ 500psi.................................................................4-131 Compressor Description ...............................................................................................4-143 Air Inlet System ....................................................................................................................... 4-143 Instrument Group 4-145 Protection System 4-145 Compressor Operation .................................................................................................4-146 Section 3 Operation .............................................................................................................4-146 General ....4-146 Purpose Of Controls ...4-146 Initial Start-up Procedure .........................................................................................................4-148 Subsequent Start-up Procedure 4-149 Shutdown Procedure .4-149 General Operating Instructions ...............................................................................................4-149 Compressor Maintenance ............................................................................................4-150 Section 4 General Maintenance......................................................................................... 4-150 General ...................................................................................................................................4-150 Daily Operation 4-150 Maintenance After Initial 50 Hours Of Operation 4-151 Maintenance Every 250 Hours ................................................................................................ 4-151 Maintenance Every 500 Hours 4-151 Maintenance Every 1000 Hours 4-151 Main Drive Shaft Seal Replacement ....................................................................................... 4-152 Interstage Tube....................................................................................................................... 4-155 Discharge Check Valve .4-156 Separator/Receiver Tank.........................................................................................................4-157 Minimum Pressure / Check Valve 4-159 Scavenge Line 4-160 Scavenge Line Sight Glass .....................................................................................................4-160 Scavenge Line Oriface............................................................................................................4-160 Compressor Discharge Temperature Switches, Senders and Gauges 4-161 Thermal/Bypass Valve ............................................................................................................4-162 Fluid Stop Valve 4-164 Compressor Fluid Filter ..4-166 Inlet Valve ................................................................................................................................4-168 Compressor Regulation.......................................................................................................4-170 Relieving Regulators...............................................................................................................4-170 Reducing Regulators ..............................................................................................................4-173 System Blowdown Valve .........................................................................................................4-175 Running Blowdown Valve ........................................................................................................4-176 BI620428

Table of Contents

SKSS Introduction ix Table of Contents Moisture Separator Maintenance 4-178 Auxiliary Regulator 4-179 Troubleshooting ....................................................................................................................... 4-181 Compressor Oil Cooler Assembly ................................................................................ 4-185 Compressor oil cooler ...4-185 Radiator/Hydraulic Oil Cooler Assembly ..................................................................... 4-186 Radiator/Oil Cooler Repair ............................................................................................4-187 High Pressure Compressor Fluid Cooler .................................................................... 4-189 Radiator Cooler ..............................................................................................................4-197 Section 5 Dust Control Systems..................................................................... 5-1 Water Injection ....................................................................................................................5-3 Water Injection Control .......5-4 Basic Water Injection System - SKSS-15 ..................................................................................5-6 Water Pump........................................................................................................................5-7 Recommended Lubricants............................................................................................................9 Water Pump Motor Repair .............................................................................................................9 Water Pump Motor ..............................................................................................................10 Foam Injection System .......................................................................................................18 Foam Injection Pump .........................................................................................................20 Section 6 Mast / Rotary Drive / Pipe Rack....................................................... 6-1 Mast Weldment ...................................................................................................................6-2 Mast Repair ............6-3 Mast Assembly .6-3 Mast Pivot ..............6-4 Feed Cylinders ...................................................................................................................6-5 Feed Cylinder - Removal ...........................................................................................................6-7 Feed Cylinder Assembly ...................................................................................................6-9 Repair...................................................................................................................................... 6-10 Installation ................................................................................................................................6-10 Hoist/Pulldown Cable Adjustment .................................................................................6-11 Hoist/Pulldown Cable Replacement ..............................................................................6-14 Rotary Head Guide Alignment ........................................................................................6-16 Rotary Drive Assembly ....................................................................................................6-18 Rotary Drive - Removal from Mast 6-19 Rotary Drive - Installation .........................................................................................................6-19 Rotary Drive Gearbox ......................................................................................................6-20 Rotary Drive Gearbox - Item Listing .........................................................................................6-21 Rotary Head Bull Shaft Bearing ................................................................................................6-21 Rotary Drive Gearbox - Repair .................................................................................................6-22 Main Shaft Bearing Preload .6-22 Air Swivel 6-23 BI620428

x SKSS Introduction

Winch Assembly ..............................................................................................................6-24 Precautions on the Use of Winches 6-24 Wire Rope ................................................................................................................................ 6-24 Wedge Sockets .....6-26 Grooved Drums .....6-27 Plain (Smooth) Drums .............................................................................................................6-27 Drums - Multiple Layers ...6-27 Winch Assembly Service Manual 6-28 Deck Wrench .................................................................................................................... 6-57 H.O.B.O. Wrench ..............................................................................................................6-58 Breakout System - HOBO .......................................................................................................6-59 Pipe Safety Arm .......6-59 Pipe Positioner .................................................................................................................6-60 Carousel Pipe Rack .........................................................................................................6-61 Major Components ................................................................................................................6-6-61 Carousal Indexing ......6-62 Pipe Rack Bearings - Removal ................................................................................................6-64 Pipe Rack Components - Inspection ....................................................................................... 6-67 Pipe Rack - Assembly and Installation 6-68 Pipe Rack Roller - Remove and Replace 6-69 Pipe Rack Roller - Disassembly and Assembly ....................................................................... 6-71 Section 7 Hydraulic Systems .......................................................................... 7-1 Hydraulic Symbols ............................................................................................................7-2 Pressure Setting Sequence ..............................................................................................7-4 Hydraulic Tank ...................................................................................................................7-6 Main Return and Case Drain Filter ...................................................................................7-8 Main Hydraulic Pumps ....................................................................................................7-10 Pump Identification ........7-11 Right Track, Left Track/Rotation Pumps ........................................................................7-11 Hydraulic Piston Pumps - Repair ..............................................................................................7-11 AA4VG 180 Hydraulic Pump .....................................................................................................7-13 HD/D Control 7-13 Port Locations .......................................................................................................................... 7-15 Setting Procedure ......7-15 Mechanical Zero Position - HD Pump Control 7-16 Hydraulic Zero Position - HD Pump Control .............................................................................7-17 Charge Pressure, High Pressure and P.O.R. Relief Settings 7-18 Set Charge Pressure ...7-19 Set Crossover Relief (High Pressure) ...................................................................................... 7-19 Set Pressure Override (P.O.R.)...............................................................................................7-21 Charge Filter .....................................................................................................................7-22 Tram/Rotation Pump Circuit ...........................................................................................7-24 Tram/Rotation Pump Circuit 7-25 Rotation Circuit 7-26 BI620428

Table of Contents

SKSS Introduction xi Table of Contents Rotation/Tram Motor Circuit .7-27 Loop Filters ......................................................................................................................7-28 Rotary Drive Gearbox Motor...........................................................................................7-32 Rotary Drive Gearbox Motor - Repair 7-32 Case leakage bypass test ........................................................................................................7-32 Shaft Seal Replacement .7-32 Trouble Shooting .......7-34 Feed and Auxiliary Pump Circuit ....................................................................................7-36 Hydraulic Piston Pumps - Repair .............................................................................................7-36 Feed & Auxiliary Functions Pump............................................................................................ 7-37 Function of Load Sensing Control (DRS) ................................................................................. 7-37 Adjustment Procedure ..7-37 Standby Pressure: ......7-37 Main Pressure: .........................................................................................................................7-37 Auxiliary and Feed Circuits ...7-38 Main Control Valves.........................................................................................................7-39 Valve Stand Assembly ...7-39 MP18 Valve - Jack and Mast Raise Valve.......................................................................7-40 MP22 Valve - Hoist and Pulldown Control.....................................................................7-42 MP22 Valve.......................................................................................................................7-44 4WE6 - Aux. Functions and Mast Valves .......................................................................7-45 Exploded View of 4WE6 .7-49 Counterbalance Valve .....................................................................................................7-49 Counterbalance Valve Adjustments .......................................................................................... 7-49 Pilot Control Manifold ......................................................................................................7-50 Control Valve Assembly ..................................................................................................7-52 Auxiliary Pump Load Solenoid Valve - V03 7-52 Shuttle Valve - V04 .......7-52 Auxiliary Pump Load Sense Relief - V05 .................................................................................. 7-52 Jacks/Mast raise Load Sense relief - V06 7-53 Drill/Tram Interlock Solenoid Valve - V07 7-53 Drill/Tram Solenoid Valve - V08............................................................................................... 7-54 Auto Pulldown Solenoid Valve - V09 7-54 Pilot Operated Directional Valve - V10......................................................................................7-54 Set-up Interlock Solenoid Valve - V11.......................................................................................7-54 Auto Pulldown Pressure Reducing Valve - V12 7-55 Shuttle Valve - V13 .......7-55 Surge Protection Relief Valve - V14.........................................................................................7-55 Maximum Pulldown Pressure Relief - V15.................................... 7-56 2nd Maximum Pulldown Relief Valve - V16 7-56 Reduced Pulldown Relief Valve - V17 ...................................................................................... 7-56 Reduced Pulldown Solenoid Valve - V18 7-57 Shuttle Valve - V19 .......7-57 Orifice - V20............................................................................................................................. 7-57 Maximum Rotation Pressure Relief - V21 7-57 Surge Protection Pressure Reducing/Relieving Valve - V22....................................................7-57 Hydraulic Feed Circuit .....................................................................................................7-58 Hoist/Pulldown Control Valve 410665 MP22........................................................... 7-59 BI620428

• 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