Cat Bucyrus Terex Series SKF-12 Infinity Blasthole Drill Service Manual SN 1D68E74 – PDF DOWNLOAD by www.heydownloads.com

Technical Manual

BI620409

BUCYRUS

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Service Manual Serial No. 1D68E74 Inﬁnity Blasthole Drill Series SKF-12 BI620409

Parts Ordering and 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. Rock Drills have the serial number stamped on the cylinder.

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 motor freight collect 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.

Introduction i

MAILING ADDRESS FOR PARTS ORDER ENTRY SHIPPING ADDRESS Terex Reedrill QLD Terex Reedrill QLD Terex Reedrill QLD P. O. Box 5729 Telephone (07) 4952 5600 10-12 Corporate Dve Mackay QLD, 4741 Fax (07) 4952 5311 Mackay QLD, 4741 Australian Branches Kelmscott Brisbane Newcastle Lot 21 Bryant Rd 585 Curtain Ave East 139 Racecourse Rd Kelscott WA 6111 Ea gle Farm QLD 4009 Rutherford NSW 2320 Ph. (08) 9495 7700 Ph. (07) 3632 4600 Ph. (02) 4932 0000 Fax (08) 9495 7750 Fax. (07) 3216 3934 Fax (02) 4932 0733 © TEREX REEDRILL 2006 BI620409

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

* Study Engine Operator and Maintenance Manual

* 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 Delivered : _________________________________

Dealer : ____________________________________________

Customer : _________________________________________

ii Introduction

BI620409

Product Description

WARNING: DO NOT use this machine for any other purpose than blasthole drilling.

The SKF series rotary blasthole drill is 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 SKF-12 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 triple cleated grousers.

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.

Introduction iii

BI620409

SKF-12 Component Locator

COTT ONREEL

CRANECONTROLS

OPERATORSCABIN

A/C PRESS URISER

CABAIRCONDITIONER

FIRESUPPRESS ION ACTUACTOR

E /STOP

T RANSDUCERBOX

MAIN ELECTRICALCABINET

HYD T ANK

MAS TRAISECYLINDER

FIRESUPPRESSIONTANKS

90LTQUELLT ANK

ENGINE

CATERPILLAR 3412E

COMPRESSOROILCOOLER CHARGEAIRCOOLER

E/STOP

FIRESUPPRESSIONACTUACTOR

COMPRESSOR

SULL AI R1150 cfm/350psi

WIGGINSBOX

WATERTANKS

E NGINE AIRCLEANER

ROTARYDRIVE

CRANE

AUT OMATICBREAKOUT WRENCH (HOBO)

FIRESUPP RE SSIO NACTUACTOR

E/STOP

T OOLBOX

EMERGENCYACCESS LADDER

THREADGREASER

CENTRALLUBE

HAMMEROIL

PUMPDRIV EBOX

DRIV E LINE

ISOLATORBOX

BATTE RY BOX

ENGINERADIATORHYD

OILCOOLE R/ CHARGE AIRCOOLER

MUFFLER

E MERGENCY ACCESS LADDER

E /STOP FIRE SUPP RESS ION ACTUACTOR

COMPRESSO R AIRCLEANER

MAST ACCESS LADDER

AIRRECEIVE RTANK

BEANPUMP

iv Introduction

Fig. i-1 SKF-12 Top View

BI620409

Introduction v

TER EX

SKF-12 Component Locator

MASTACCESSLADDER

DUST SKIRT ISOLATO RBOX BATTERY BOX 90LT QUELLT ANK

LIGHT

E/STOP

BI620409

SAFETY LINE FIRESUPPRESSIONTANKS MAST ACCESS LADDER

LIGHTS

FIRE SUPPRESSION ACTUATOR

FIRESUPPRESS

ION ACT UACTOR

vi Introduction

Contents Introduction Ordering Information / Product Support ...................................................................................i Safety Information ......................................................................................................................ii Product Description ..................................................................................................................iii Component Locator ..................................................................................................................iv Section 1 Safety Overview of Potential Hazards ...............................................................................................1-2 Safety .......................................................................................................................................1-2 Personal Protective Equipment ..........................................................................................................1-2 Noise ..................................................................................................................................................1-2 Electrical Contact ...............................................................................................................................1-2 Overhead and Buried Utilities ............................................................................................................1-2 Clearance from High Voltage Lines ....................................................................................................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 General Locator .................................................................................................................................1-9 Section 2 Operator's cab / Controls Graphic Symbol Legend .........................................................................................................2-2 Warning Decals .......................................................................................................................2-6 Operator Control Panel ...........................................................................................................2-8 System Pressure Gauge Panel ............................................................................................2-11 Switch Panel ..........................................................................................................................2-12 Switches/Diagnostic Control Panel .....................................................................................2-15 Cab Heater Fault Isolation ....................................................................................................2-16 AC/Heater/Pressurizer Unit ..................................................................................................2-17 Air Conditioner .....................................................................................................................2-18 Section 3 Mainframe / Crawlers Leveling Jacks .........................................................................................................................3-2 Remove ..............................................................................................................................................3-3 Repair .................................................................................................................................................3-3 Replace ..............................................................................................................................................3-3 Lubricating Jack Casings ...................................................................................................................3-3 Mast Elevating Cylinders ........................................................................................................3-4 Remove ..............................................................................................................................................3-5 BI620409

Table of

Table BI620409

of Contents

Introduction vii

Section 3 Mainframe / Crawlers Repair .................................................................................................................................................3-5 Replace ..............................................................................................................................................3-5 Crawler Assembly ...................................................................................................................3-6 Crawler Component Repair ................................................................................................................3-7 Crawler Serial Number Location ............................................................................................3-7 Metric Bolt Torque Speciﬁcations .........................................................................................3-8 Track Maintenance ..................................................................................................................3-9 Before Operating the Machine ...........................................................................................................3-9 General Maintenance .........................................................................................................................3-9 Track Tension Adjustment ....................................................................................................3-10 Track Chain ............................................................................................................................3-12 Separate ...........................................................................................................................................3-12 Track Link Repair & Replace............................................................................................................3-14 Track Shoes ...........................................................................................................................3-16 Mounting to Track Chain ..................................................................................................................3-16 Track Shoe Bolt Torque (Direct Torque Method) ..............................................................................3-17 Track Shoe Bolt Torque (Torque Turn Method) ................................................................................3-17 Track Assembly .....................................................................................................................3-20 Track Chain & Shoe - Assembly & Installation .................................................................................3-20 Final Drive ..............................................................................................................................3-22 General Description .........................................................................................................................3-22 Removal from Track Frame ..............................................................................................................3-23 Installation into Track Frame ............................................................................................................3-24 Oil Check/Change ............................................................................................................................3-25 Oil Speciﬁcations ..............................................................................................................................3-26 Recommended Oils ..........................................................................................................................3-26 Temperature Range Chart ................................................................................................................3-27 Final Drive Assembly ............................................................................................................3-28 Parking Brake - Description .............................................................................................................3-30 Parking Brake - Removal & Installation ............................................................................................3-31 Towing Procedure ............................................................................................................................3-31 Final Drive Assembly Manual ...............................................................................................3-33 Idler Unit .................................................................................................................................3-90 General Description .........................................................................................................................3-90 Idler Assembly ..................................................................................................................................3-91 Removal & Disassembly ..................................................................................................................3-92 Assembly & Installation ....................................................................................................................3-94 Track Tension Unit ................................................................................................................3-96 Installation ........................................................................................................................................3-97 Track Rollers ..........................................................................................................................3-98 General Description .........................................................................................................................3-98 Track Roller Assembly......................................................................................................................3-99 Removal & Disassembly ................................................................................................................3-100 Assembly ........................................................................................................................................3-101 Test & Install ...................................................................................................................................3-102

Section 3 Mainframe / Crawlers

viii Introduction

Engine Service Procedures ....................................................................................................4-3 Power Train ........................................................................................................................................4-3 Caterpillar 3412E Engine ...................................................................................................................4-4 Engine and Compressor Air Cleaner Service .....................................................................................4-5 Flexible Drive Coupling ..........................................................................................................4-6 Pump Drive ............................................................................................................................4-10 Pump Drive Assembly - Removal and Replacement .......................................................................4-10 Pump Drive Gearbox - Repair ..........................................................................................................4-12 Hydraulic Pumps ...................................................................................................................4-13 Compressor Service Procedures ........................................................................................4-15 Compressor Drive Coupling - Removal and Replacement ..............................................................4-16 Mounting Instructions for Arcusaﬂex Flywheel Couplings ................................................................4-18 Taper-Loc Bushing Installation .........................................................................................................4-18 Before Installation and Start-Up of New or Rebuilt Compressor ......................................................4-19 Compressor Unit - Installation ..........................................................................................................4-19 High Pressure Compressor ..................................................................................................4-20 Safety ...............................................................................................................................................4-20 Description .......................................................................................................................................4-23 Compressed Air Functions ...............................................................................................................4-23 Compressor Fluid Circuit .....................................................................................................4-27 Compressor Condensation Table ........................................................................................4-29 Compressor Functional Description ...................................................................................4-30 Compressor Operation .........................................................................................................4-33 Compressor Air Circuit ....................................................................................................................4-38 Initial Start-up Procedure .................................................................................................................4-39 Regulator Set-up ..............................................................................................................................4-39 Subsequent Start-up Procedure .......................................................................................................4-40 Shutdown Procedure ........................................................................................................................4-40 General Operating Instructions ........................................................................................................4-40 General Maintenance ............................................................................................................4-40 Daily Operation ................................................................................................................................4-41 50, 250, 500, & 1000 Hours .............................................................................................................4-41 Compressor Maintenance ....................................................................................................4-42 Main Drive Shaft Seal Replacement ................................................................................................4-42 Interstage Tube ................................................................................................................................4-44 Discharge Check Valve ....................................................................................................................4-45 Support Rollers ...................................................................................................................3-103 General Description .......................................................................................................................3-103 Support Roller Assembly ................................................................................................................3-104 Removal & Disassembly ................................................................................................................3-105 Assembly ........................................................................................................................................3-106

Table of Contents Section 4 Engine / Drive train / Compressor

BI620409

Section 4 Engine / Drive train / Compressor

Section 5 Dust Control Systems

Section 6 Mast / Rotary drive / Pipe rack

Introduction ix Table of Contents

Dust Control System Functions ............................................................................................5-2 Basic Water Injection Circuit ..............................................................................................................5-2 Water Injection Circuit ............................................................................................................5-3 Dust Collector/Water Injection Pressure Adjustment ..........................................................5-5 Water Pump Assembly............................................................................................................5-6 Water Pump Service Manual..............................................................................................................5-7 Water Pump Motor Service Manual .................................................................................................5-32

12 Meter Mast Assembly .........................................................................................................6-2 Cable Tensioning Assembly ...................................................................................................6-3 Feed Cylinder - Removal and Installation .............................................................................6-4 SKF-12 Feed Cylinder .............................................................................................................6-6 Cylinder Repair ..................................................................................................................................6-7 Hoist / Pulldown Cable Adjustment .......................................................................................6-8 Auto Tensioning (optional) - Operating Principle ..............................................................................6-11 Auto Tensioning - Cable Installation & Adjustment ...........................................................................6-14 Hoist / Pulldown Cable Replacement ..................................................................................6-16 Rotary Head Guide Alignment ............................................................................................6-17 Separator/Receiver Tank ..................................................................................................................4-46 Minimum Pressure Check Valve ......................................................................................................4-47 Scavenge Line .................................................................................................................................4-48 Compressor Discharge Temperature Switches, Senders, & Gauges ..............................................4-49 Thermal Bypass Valve......................................................................................................................4-51 Compressor Fluid Filter ....................................................................................................................4-54 Fluid Stop Valve ...............................................................................................................................4-56 Inlet Valve .........................................................................................................................................4-58 Relieving Regulators ........................................................................................................................4-59 Reducing Regulators ........................................................................................................................4-61 System Blowdown Valve ..................................................................................................................4-63 Running Blowdown Valve .................................................................................................................4-64 Moisture Separator ...........................................................................................................................4-66 Troubleshooting................................................................................................................................4-66 Recommended Spare Parts Listing .................................................................................................4-68 Fan/Oil Cooler Piping ............................................................................................................4-69 Fan Motor and Fan Installation ............................................................................................4-70 Radiator/Oil Cooler Repair ...................................................................................................4-72 Mesabi Radiator & Cores Service Manual .......................................................................................4-73 High Pressure Compressor Fluid Cooler ............................................................................4-81

BI620409

Section 6 Mast / Rotary drive / Pipe rack

Section 7 Hydraulic systems

x Introduction Rotary Drive Assembly ........................................................................................................6-19 Removal from Mast ..........................................................................................................................6-20 Installation .............................................................................................................................6-20 Rotary Drive Gearbox ...........................................................................................................6-21 Rotary Drive Assembly and Parts List ..............................................................................................6-21 Rotary Drive Gearbox - Repair Manual ............................................................................................6-23 Air Swivel .........................................................................................................................................6-63 Rotary Drive Motor - Repair .............................................................................................................6-26 Winch Assembly ....................................................................................................................6-66 Precautions on the Use of Winches .................................................................................................6-66 Wire Rope ........................................................................................................................................6-66 Wedge Sockets ................................................................................................................................6-68 Grooved Drums ................................................................................................................................6-69 Plain (Smooth) Drums ......................................................................................................................6-69 Drums - Multiple Layers ...................................................................................................................6-71 Winch Service Manual - Model BG8A ..............................................................................................6-73 Deck Wrench........................................................................................................................6-104 H.O.B.O. Wrench .................................................................................................................6-105 Tong Dies .......................................................................................................................................6-106 Pipe Positioner ....................................................................................................................6-107 Carousel Pipe Rack .............................................................................................................6-108 Chain Drive - Adjust/Replace .........................................................................................................6-108 Pipe Rack Bearings - Replace .......................................................................................................6-109 Carousel Top Tube Bearing - Replace ...........................................................................................6-110 Carousel Lower Bearing - Replace ................................................................................................6-113 Carousel Pivot Support Upper Bearing - Replace ..........................................................................6-115 Carousel Pivot Support Lower Bearing - Replace ..........................................................................6-117 Carousel Pivot Support Mid-Point Bearing - Replace ....................................................................6-118

Hydraulic Symbols ..................................................................................................................7-2 Hydraulic Tank .........................................................................................................................7-4 Hydraulic System ....................................................................................................................7-5 Pressure Setting Sequence ...............................................................................................................7-6 Main Return and Case Drain Filters ......................................................................................7-7 Routine Maintenance .........................................................................................................................7-8 Changing Filter Elements ...................................................................................................................7-8 Main Hydraulic Pumps ............................................................................................................7-9 Hydraulic Pump - Identiﬁcation ..........................................................................................................7-9 Hydraulic Piston Pumps - Removal and Replacement ....................................................................7-10 Right Track/Pulldown, Left Track/Rotation Pumps ..............................................................7-6 Technical Data ..................................................................................................................................7-11 AA4VG 125 Hydraulic Pump EP2 Control .......................................................................................7-13

BI620409

Section 7 Hydraulic systems

Introduction xi Table of Contents

AA4VG EP Contoller ........................................................................................................................7-14 EP (24VDC) Control .........................................................................................................................7-15 Adjustment of Drill and Tram Controllers .........................................................................................7-16 Start-Up Procedure ..........................................................................................................................7-17 Connections .....................................................................................................................................7-19 Before Making Pump Adjustments ...................................................................................................7-20 Mechanical Zero Position Adjustment ..............................................................................................7-21 Hydraulic Centering Adjustment .......................................................................................................7-22 Set Charge Pressure ........................................................................................................................7-24 Set Pressure Override (P.O.R.) ........................................................................................................7-24 Set Crossover Relief (High Pressure) ..............................................................................................7-26 Removal and Installation ..................................................................................................................7-27 Hydraulic Piston Pumps - Maintenance ..............................................................................7-28 Hydraulic Piston Pump - Trouble Shooting ........................................................................7-30 Charge Circuit .......................................................................................................................7-34 Charge Circuit Gear Pump ...............................................................................................................7-34 Routine Maintenance .......................................................................................................................7-37 Changing Filter Elements .................................................................................................................7-37 Loop Filters ............................................................................................................................7-38 Routine Maintenance .......................................................................................................................7-41 Changing Filter Elements .................................................................................................................7-41 Diverter Valve ........................................................................................................................7-42 Operation .........................................................................................................................................7-42 Hydraulic Feed and Rotation Circuits .................................................................................7-43 Basic Rotation Circuit .......................................................................................................................7-43 Rotation Circuit .................................................................................................................................7-44 Basic Pulldown Circuit ......................................................................................................................7-45 Hoist / Pulldown Circuit ....................................................................................................................7-46 Drill / Tram Control Circuit ...................................................................................................7-47 Operation .........................................................................................................................................7-47 Drill / Tram Circuit .............................................................................................................................7-49 Rope Tensioning Circuit .......................................................................................................7-50 Rotary Drive Gearbox Motor ................................................................................................7-51 Technical Data ..................................................................................................................................7-52 Shaft Seal Replacement ..................................................................................................................7-58 Installation ........................................................................................................................................7-59 Start-Up Procedure ..........................................................................................................................7-60 Troubleshooting Procedure ..............................................................................................................7-61 Routine Maintenance .......................................................................................................................7-64 Port Information ................................................................................................................................7-65 Fan and Auxiliary Pump Circuit ...........................................................................................7-65 Fan and Auxiliary Functions Pump ...................................................................................................7-67 Function of Load Sensing Control ....................................................................................................7-67 Standby Pressure .............................................................................................................................7-67 BI620409

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

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

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