Issuu

Technical Manual

BI620436

BUCYRUS

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Service Manual for Serial No. 1D67C80 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 BI620436

BI620436

Parts Ordering & Product Support

Use only genuine Terex Reedrill parts in the maintenance, rebuild, or repair, of Terex Reedrill machines. Terex 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 Terex Reedrill WATerex Reedrill WATerex Reedrill 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 BI620436

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

BI620436

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 Terex 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

BI620436

iv SKSS Introduction

Contents Introduction Parts Ordering & Product Support.....................................................................................i Safety Information ...............................................................................................................ii Product Description ...........................................................................................................iii Manual Contents ................................................................................................................ iii Table of Contents...............................................................................................................iv General Locators .............................................................................................................xvii 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 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 Operating Instructions..............................................................................................................2-32 BI620436

Table of

SKSS Introduction v Table of Contents Routine Maintenance Procedures ............................................................................................ 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 Replace......................................................................................................................................3-4 Mast Elevating Cylinders .................................................................................................3-5 Remove .....................................................................................................................................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 Direct Torque Method...............................................................................................................3-27 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 BI620436

vi SKSS Introduction

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 Hiab Hydraulic Crane...............................................................................................................3-56 Load Lift Capacities........................................................................................................... 3-56 Maintenance .............................................................................................................................3-57 Fuel Tank Fill Assembly .................................................................................................3-58 Hydraflo Fuel Fill....................................................................................................................... 3-58 Troubleshooting ........................................................................................................................ 3-59 Section 4 Engine / Drive Train / Compressor ................................................ 4-1 Power Group Locator......................................................................................................4-2 Engine ...............................................................................................................................4-3 Engine Fuel System.................................................................................................................4-4 Oil Reserve Systems.............................................................................................................4-12 Engine Oil Reserve System Circuit......................................................................................... 4-12 Engine Oil Reserve System.....................................................................................................4-12 LED Monitor Readings.............................................................................................................4-13 Signals..................................................................................................................................... 4-13 Adjustment of Running Oil Level..............................................................................................4-13 BI620436

Table of Contents

SKSS Introduction vii Table of Contents Wiring Diagram................................................................................................................. 4-14 Oil Pressure Switch.................................................................................................................4-14 Servicing.................................................................................................................................. 4-14 Troubleshooting ........................................................................................................................ 4-15 Oil Reserves Systems - Maintenance...................................................................................... 4-15 Engine and Compressor Air Cleaners.......................................................................... 4-16 Engine and Compressor Air Cleaner Service.................................................................... 4-17 Inspection and General Service...............................................................................................4-17 Engine and Compressor Air Cleaner Service.......................................................................... 4-18 Safety Element Service............................................................................................................4-19 Flexible Drive Coupling Service....................................................................................4-20 Adaptor Flanges 4-20 Centering Flanges.............................................................................................................. 4-20 Rubber Element................................................................................................................. 4-20 Tube Assembly.................................................................................................................. 4-20 Mounting Screws and Adhesive............................................................................................... 4-21 Pump Drive..................................................................................................................... 4-23 Pump Identification ................................................................................................................... 4-23 Pump Drive Assembly - Removal and Replacement 4-24 Pump Drive Gearbox......................................................................................................4-25 Pump Drive Gearbox - Repair..................................................................................................4-26 3" Input Shaft Assembly...........................................................................................................4-28 Hydraulic Pumps ............................................................................................................4-29 Compressor Installation................................................................................................4-30 Compressor Drive Coupling-Removal and Replacement........................................................ 4-31 Compressor Unit - Installation..................................................................................................4-32 Before Start-Up of New or Rebuilt Compressor: ...................................................................... 4-34 Drill Compressor ............................................................................................................4-35 High Pressure Compressor ...........................................................................................4-36 Section 1 Safety..................................................................................................................... 4-36 General ....................................................................................................................................4-36 Pressure Release....................................................................................................................4-36 Fire and Explosion............................................................................................................. 4-37 Moving Parts 4-37 Toxic and Irritating Substances................................................................................................ 4-37 Electrical Shock....................................................................................................................... 4-38 Lifting 4-38 Section 2 Description............................................................................................................4-39 Introduction ............................................................................................................................... 4-39 Compressed Air Functions......................................................................................................4-39 Sullair Compressor Unit...........................................................................................................4-40 Compressor Discharge System .............................................................................................. 4-41 Compressor Cooling and Lubrication System................. 4-42 Compressor Fluid Circuit ..............................................................................................4-43 Compressor Condensation Table.................................................................................4-46 Compressor Air Circuit 1475cfm @ 500psi...................................................................4-47 Compressor Air Circuit.............................................................................................................4-48 Compressor Functional Description ............................................................................4-61 Air Inlet System............................................................................................................... 4-61 BI620436

viii SKSS Introduction

Lubrication Guide ..................................................................................................................... 4-61 Application Guide 4-61 Capacity Control System With Poppet Valve, Functional Description...................................... 4-62 Start Mode................................................................................................................................ 4-62 Normal Operation............................................................................................................... 4-62 Modulating Mode 4-62 Unload Mode ............................................................................................................................4-62 Shutdown Mode .....4-63 Instrument Group............................................................................................................... 4-63 Protection System.................................................................................................................... 4-63 Compressor Operation ..................................................................................................4-64 Section 3 Operation..............................................................................................................4-64 General .....4-64 Purpose Of Controls................................................................................................................4-64 Initial Start-up Procedure..........................................................................................................4-66 Subsequent Start-up Procedure...............................................................................................4-67 Shutdown Procedure...............................................................................................................4-67 General Operating Instructions................................................................................................4-67 Compressor Maintenance .............................................................................................4-68 Section 4 General Maintenance.......................................................................................... 4-68 General .....4-68 Daily Operation................................................................................................................ 4-68 Maintenance After Initial 50 Hours Of Operation ....................................................................... 4-69 Maintenance Every 250 Hours.................................................................................................4-69 Maintenance Every 500 Hours.................................................................................................4-69 Maintenance Every 1000 Hours............................................................................................... 4-69 Main Drive Shaft Seal Replacement........................................................................................ 4-70 Interstage Tube........................................................................................................................ 4-73 Discharge Check Valve............................................................................................................4-74 Separator/Receiver Tank..........................................................................................................4-75 Minimum Pressure / Check Valve 4-77 Scavenge Line......................................................................................................................... 4-78 Scavenge Line Sight Glass...................................................................................................... 4-78 Scavenge Line Oriface.............................................................................................................4-78 Compressor Discharge Temperature Switches, Senders and Gauges ................................... 4-79 Thermal/Bypass Valve.............................................................................................................4-80 Fluid Stop Valve 4-82 Compressor Fluid Filter...........................................................................................................4-84 Inlet Valve ..4-86 Compressor Regulation........................................................................................................4-88 Relieving Regulators................................................................................................................4-88 Reducing Regulators...............................................................................................................4-91 System Blowdown Valve.......................................................................................................... 4-93 Running Blowdown Valve......................................................................................................... 4-94 Moisture Separator Maintenance ..............................................................................................4-96 Auxiliary Regulator 4-97 Troubleshooting ....................................................................................................................... 4-101 Compressor Oil Cooler Assembly ...............................................................................4-105 Compressor oil cooler.............................................................................................................4-105 BI620436

SKSS Introduction ix Table of Contents Radiator/Hydraulic Oil Cooler Assembly ....................................................................4-106 Radiator/Oil Cooler Repair ...........................................................................................4-107 High Pressure Compressor Fluid Cooler...................................................................4-109 Radiator Cooler............................................................................................................4-117 Section 5 Dust Control Systems..................................................................... 5-1 Water Injection ..................................................................................................................5-3 Water Tanks...............................................................................................................................5-3 Water Tank Top-up Solenoid Valve.............................................................................................5-4 Water Injection Relief Valve........................................................................................................5-6 Water Injection Control...............................................................................................................5-7 Basic Water Injection System - SKSS-15..................................................................................5-9 Water Pump..................................................................................................................... 5-10 Pump Specifications................................................................................................................5-10 Servicing Instructions............................................................................................................... 5-10 Parts List...................................................................................................................................5-11 Recommended Lubricants......................................................................................................5-16 Water Injection Valve......................................................................................................5-17 Water Injection Ball Valve Assembly.........................................................................................5-17 Water Injection Ball Valve.........................................................................................................5-17 Actuator 5-18 High Pressure Cleaner ...................................................................................................5-31 Foam Injection................................................................................................................5-37 Section 6 Mast / Rotary Drive / Pipe Rack....................................................... 6-1 Mast Weldment .................................................................................................................6-2 Mast Repair................................................................................................................................6-2 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 Drive Assembly ..................................................................................................6-16 Rotary Head Guide Alignment..................................................................................................6-17 Rotary Head Drive System......................................................................................................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 Nut......................................................................................... 6-21 BI620436

x SKSS Introduction

Rotary Drive Gearbox - Repair.................................................................................................6-22 Main Shaft Bearing Preload......................................................................................................6-22 Air Swivel 6-23 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 Hydraulic Winch Repair...........................................................................................................6-29 Deck Wrench..................................................................................................................6-60 H.O.B.O. Wrench .............................................................................................................6-61 Breakout System - HOBO.......................................................................................................6-62 Pipe Safety Arm................................................................................................................ 6-62 Pipe Positioner...............................................................................................................6-63 Carousel Pipe Rack ........................................................................................................6-64 Major Components...................................................................................................................6-64 Carousal 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 Systems .......................................................................... 7-1 Hydraulic Symbols ...........................................................................................................7-2 Pressure Setting Sequence .............................................................................................7-4 Hydraulic Tank..................................................................................................................7-6 Return Hydraulic Filters..............................................................................................................7-7 Main Return and Case Drain Filter..................................................................................7-8 Main Hydraulic Pumps...................................................................................................7-10 Pump Identification ................................................................................................................... 7-10 Right Track, Left Track/Rotation Pumps.......................................................................7-11 Hydraulic Piston Pumps Removal and Repair..........................................................................7-11 Hydraulic Piston Pumps - Operation Specifications Adjustment and Repair............................7-11 HD/D Control............................................................................................................................ 7-12 Technical Data................................................................................................................. 7-14 Port Locations................................................................................................................. 7-18 Setting Procedure.................................................................................................................... 7-19 Charge Pressure, High Pressure and P.O.R. Relief Settings 7-20 Set Charge Pressure...............................................................................................................7-20 Set Crossover Relief (High Pressure)...................................................................................... 7-21 Set Pressure Override (P.O.R.)...............................................................................................7-22 Mechanical Zero Position - HD Pump Control 7-23 BI620436

Table of Contents

• 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