Technical Manual
© Bucyrus All Rights Reserved
R
BI620406
BUCYRUS
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
Think Terex, Think Integrity SKF-12 Infinity Blasthole Drill Serial No.1S68A05 Service Manual SERVICE MANUAL PART NO. 91-A11-625 October 2009, Version 1 BI620406
BI620406
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 unauthorised 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.
Effective Date: August, 2007. Product specifications and prices are subject to change without notice or obligation. The photographs and/or drawings in this document are for illustrative purposes only. Refer to the appropriate Operator’s Manual for instructions on the proper use of this equipment. Failure to follow the appropriate Operator’s Manual when using our equipment or to otherwise act irresponsibly may result in serious injury or death. The only warranty applicable to our equipment is the standard written warranty applicable to the particular product and sale and Terex makes no other warranty, express or implied. Products and services listed may be trademarks, service marks or trade-names of Terex Corporation and/or its subsidiaries in the USA and other countries. All rights are reserved. Terex® is a registered trademark of Terex Corporation in the USA and many other countries. Copyright (or ©) 2007 Terex Corporation.
Your co-operation in furnishing as much information as possible will assist us in filling your orders correctly and in the shortest possible time.
1. IDENTIFICATION OF THE MACHINE
Always furnish the Reedrill Model Number and Serial Number when ordering parts. This information is found on the machine nameplate.
2. PART NUMBER AND DESCRIPTION
In addition to the Serial Number, always give the part number and description of each part ordered. If there is any doubt as to the correct part number and description, furnish a dimensioned sketch or return the part to be replaced, transportation charges prepaid.
3. SHIPMENT
Unless otherwise instructed, all shipments will be made via road freight and charged on our invoice. Shipments cannot be made on open account until your credit has been approved by our Accounting Department.
MAILING ADDRESSFOR PARTS ORDER ENTRYSHIPPING ADDRESS Terex WA Telephone 1300 883 677 Terex WA 2 Reid Road Fax 1300 883 577 2 Reid Road Perth Int. Airport WA 6105 Perth Int. Airport WA 6105 Ph (08) 9373 6000 Fax (08) 9373 6173 AUSTRALIAN BRANCHES Brisbane Newcastle Mackay 33 Kimberley St 139 Racecourse Rd 10-12 Corporate Dve Darra QLD 4076 Rutherford NSW 2320 Mackay QLD 4740 Ph. (07) 3456 4500 Ph. (02) 4932 0000 Ph (07) 4952 0600 Fax. (07) 3456 4534 Fax (02) 4932 0733 Fax (07) 4952 0666 © TEREX 2007
SKF Introduction Int-3 Contents Parts
Product Support BI620406
Parts Ordering and Product Support
Ordering and
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
WARNING: DO NOT use this machine for any other purpose than blasthole drilling. The Infinity Series rotary blasthole drill is designed for blasthole drilling purposes only. Any other use could result in personal injury and/or property damage and will void the warranty.
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 is furnished with your Infinity Series rotary blasthole drill to aid you in performing the necessary service work to maintain your drill in good operating condition. 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 manufacturer.
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.
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 recognised 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: _____________________________________________________________________
Int-4 SKF Introduction Contents Safety Information BI620406
SKF Introduction Int-5 Contents Section 1 - Safety..............................................................................1-1 Section 1 Contents .........................................................................................................................1-3 Safety ...............................................................................................................................................1-5 Personal Protective Equipment 1-5 Noise 1-5 Electrical Contact ....................................................................................................................... 1-5 Overhead and Buried Utilities..................................................................................................... 1-5 Contact with Electric Wires 1-6 Contaminated Air 1-6 Machine Stability 1-7 Moving and Rotating Parts 1-8 High Pressure Air or Fluid .......................................................................................................... 1-8 Before Operation 1-8 During Operation 1-9 Maintenance 1-11 Safety Locator 1-12 Notes ..............................................................................................................................................1-14 Section 2 - Operator's Cab / Controls .............................................2-1 Section 2 Contents .........................................................................................................................2-3 Graphic Symbol Legend ................................................................................................................2-4 Warning Decals ...............................................................................................................................2-8 Operators Controls and Indicators .............................................................................................2-10 Operators Control Panels ......................................................................................................... 2-10 System Pressure Gauge Panel 2-13 Switch Panel 2-14 Switches / Diagnosis Control Panel 2-17 Cab Heater .....................................................................................................................................2-18 Cab Heater Fault Isolation........................................................................................................ 2-18 Air Conditioner ..............................................................................................................................2-19 TDR7BX1 Packaged Unit Manual 2-19 Section 1.0 – Introduction 2-21 Section 2.0 – Unit Specification and Settings 2-22 Section 3.0 – Technical Data and Control Settings .................................................................. 2-27 Section 4.0 – Installation and Commissioning.......................................................................... 2-29 Section 5.0 – Operating Instructions 2-41 Section 6.0 – Routine Maintenance Procedures 2-43 Section 7.0 – Fault Diagnosis 2-49 Section 8.0 Warranty 2-60 Electrical Schematic ................................................................................................................. 2-61 Notes ..............................................................................................................................................2-63 Section 3 - Main Frame / Crawlers ..................................................3-1 Section 3 Contents .........................................................................................................................3-3 Main Frame Repair – General ........................................................................................................3-5 Main Frame Repair ..................................................................................................................... 3-5 BI620406
Int-6 SKF Introduction Contents Weld Inspection Schedule .............................................................................................................3-6 Main Frame ................................................................................................................................ 3-6 Levelling Jacks ...............................................................................................................................3-7 Levelling Jacks 3-8 Levelling Jack Cylinders 3-8 Lubricating Jack Casings 3-8 Mast Elevating Cylinders ...............................................................................................................3-9 Mast Elevating Cylinders 3-9 Crawler Assembly .........................................................................................................................3-10 Crawler Assembly 3-10 Crawler Component Repair 3-10 Metric Bolt Torque Specifications ................................................................................................3-11 Track Maintenance........................................................................................................................3-12 Before Operating the Machine 3-12 General Maintenance 3-12 Track Tension Adjustment ...........................................................................................................3-13 Track Chain ...................................................................................................................................3-15 Separate Track Chain Assembly .............................................................................................. 3-15 Track Link – Repair and Replace 3-16 Track Shoes...................................................................................................................................3-18 Track Link Position 3-18 Track Shoe – Mounting to Tracks Chain 3-18 Track Shoe Bolt Torque (Direct Torque Method) .......................................................................3-20 Bolt Torque KN111 .................................................................................................................... 3-20 Track Shoe Bolt Torque (Torque Turn Method) .........................................................................3-21 Bolt Torque KN111 3-21 Track Chain and Shoe Installation ..............................................................................................3-22 Track Chain with Shoes............................................................................................................ 3-22 Track Chain and Shoe – Assembly and Installation ................................................................. 3-22 Final Drive .....................................................................................................................................3-24 General Description 3-24 Removal from Track Frame 3-25 Installation into Track Frame 3-26 Oil Check Charge ..................................................................................................................... 3-27 Final Drive Oil ................................................................................................................................3-28 Specifications 3-28 Recommended Oils 3-28 Final Drive Assembly ....................................................................................................................3-30 Final Drive Assembly ................................................................................................................ 3-30 Parking Brake – Description ..................................................................................................... 3-32 Parking Brake – Removal and Installations 3-33 Towing Procedures – Gear Drive Disconnect 3-33 Repair Manual Final Drive Model F100 3-34 A – General Instructions ........................................................................................................... 3-34 B – Safety Instructions ............................................................................................................. 3-39 C – General Specifications 3-43 BI620406
SKF Introduction Int-7 Contents D – Disassembly and Assembly Operation .............................................................................. 3-52 E – Troubleshooting ................................................................................................................. 3-86 F – Special Tools ...................................................................................................................... 3-87 Idler Unit ........................................................................................................................................3-88 General Description 3-88 Removal and Disassembly 3-90 Assembly and Installation 3-92 Track Tension Unit ........................................................................................................................3-94 Installation 3-95 Track Rollers .................................................................................................................................3-96 General Description 3-96 Track Roller Assembly 3-97 Auxiliary Crane .............................................................................................................................3-98 Palfinger Hydraulic Crane PC1300 Operators Manual 3-98 Possible Dangers ............................................................................................................... 3-99 During Operation of the Crane ......................................................................................... 3-100 Visual Inspections ............................................................................................................ 3-102 Survey of the Crane ......................................................................................................... 3-103 During Operation of the Crane ......................................................................................... 3-105 Safety Devices 3-108 Optional Features 3-111 Maintenance 3-112 Cleaning the Crane 3-118 PC1300 Specifications 3-118 Remote Winch Pendant 3-123 Notes ............................................................................................................................................3-124 Section 4 - Engine / Drive Train / Compressor...............................4-1 Section 4 Contents .........................................................................................................................4-3 Engine and Drive Train Service Procedures ................................................................................4-5 Service Procedures Outlined on the Section Include 4-5 Power Train 4-5 Engine Service Procedures 4-5 Caterpillar 3412E Engine ........................................................................................................... 4-6 Engine and Compressor Air Cleaner .......................................................................................... 4-7 Engine and Compressor Air Cleaner ............................................................................................4-8 Engine and Compressor Air Cleaner Service 4-8 Flexible Drive Coupling .................................................................................................................4-11 Flexible Drive Coupling Service ................................................................................................ 4-11 Pump Drive ....................................................................................................................................4-13 Pump Drive Assembly – Removal and Replacement 4-13 Pump Drive Gearbox ....................................................................................................................4-14 Pump Drive Gearbox – Repair 4-14 Hydraulic Pumps ..........................................................................................................................4-16 Hydraulic Pump Identification ................................................................................................... 4-16 Hydraulic Pump Removal and Replacement............................................................................ 4-17 BI620406
Int-8 SKF Introduction Contents Compressor Service Procedures ................................................................................................4-18 Compressor Drive Coupling ..................................................................................................... 4-18 Compressor Drive Coupling – Removal and Replacement 4-18 Mounting Instructions for ARCUSFLEX™ Flywheel Couplings 4-19 Taper-Loc Bushing Installation 4-20 Tightening Torques for ARCUSFLEX™ Flywheel Coupling 4-20 Before Installation and Start-up of New or Rebuilt Compressor 4-21 Compressor Unit Installation 4-21 Compressor Shaft Seal ................................................................................................................4-22 High Pressure Compressor .........................................................................................................4-25 Safety 4-25 Description 4-28 Compressed Air Functions 4-28 Compressor Oil Circuit ................................................................................................................4-32 Compressor Oil Circuit 4-32 Compressor Oil Circuit – 1150cfm @ 350psi ........................................................................... 4-32 Compressor Condensation Table ...............................................................................................4-34 Compressor Functional Description ...........................................................................................4-35 Compressor Operation .................................................................................................................4-38 Operation .................................................................................................................................. 4-38 Compressor Air Circuit – 1150cfm @ 350psi ............................................................................ 4-41 Initial Start-up Procedure.......................................................................................................... 4-42 Compressor Maintenance ............................................................................................................4-44 General Maintenance 4-44 Interstage Tube 4-46 Discharge Check Valve 4-47 Separator / Receiver Elements 4-48 Scavenge Line 4-50 Compressor Discharge Temperature Gauge, Switch and Sender 4-51 Minimum Pressure / Check Valve 4-52 Minimum Pressure / Check Valve Maintenance 4-52 Thermal Bypass Valve 4-53 Thermal Bypass Valve Maintenance 4-54 Compressor Fluid Filter 4-55 Changing Filter Elements 4-55 Fluid Stop Valve ....................................................................................................................... 4-57 Inlet Valve ................................................................................................................................. 4-59 Relieving Regulators ................................................................................................................ 4-61 Reducing Regulators ................................................................................................................ 4-63 Reducing Regulator Maintenance ............................................................................................ 4-64 System Blowdown Valve .......................................................................................................... 4-66 Running Blowdown Valve ......................................................................................................... 4-67 Running Blowdown Maintenance 4-68 Moisture Separator Maintenance 4-69 Troubleshooting 4-70 BI620406
SKF Introduction Int-9 Contents Fan / Oil Cooler Piping .................................................................................................................4-72 Fan / Oil Cooler Piping ............................................................................................................. 4-72 Fan and Motor Installation 4-73 Compressor Oil / Hydraulic Oil Cooler Service Manual ............................................................4-74 Standard Parts – High Pressure Oil Coolers 4-74 Repair Instruction – External Cleaning and Tube Removal 4-75 Repair Instruction – Seal Removal, Heater Plate Preparation and Seal Installation 4-76 Repair Instruction – Tube Installation, Final Assembly and Testing 4-77 Repair Instruction – Special Header Plate Repair 4-78 Radiator / Oil Cooler Repair .........................................................................................................4-79 Radiator Cooler Service Manual ..................................................................................................4-80 Typical Radiator Core – Standard Parts 4-80 Cleaning 4-81 Tube Removal 4-81 Seal Installation 4-82 Tube Installation ....................................................................................................................... 4-83 Notes ..............................................................................................................................................4-85 Section 5 - Dust Control System .....................................................5-1 Section 5 Contents .........................................................................................................................5-3 Dust Control System ......................................................................................................................5-5 Dust Control Systems 5-5 Water Injection ................................................................................................................................5-6 Pressure Adjustment 5-6 Water injection Circuit................................................................................................................. 5-7 Basic Water Injection System ..................................................................................................... 5-8 Water Pump .....................................................................................................................................5-9 Pump Specifications 5-9 Servicing Instructions 5-9 Water Injection Pump and Parts List 5-10 Replacing Piston Cup Seals 5-11 Replacing Suction and Discharge Valves ................................................................................. 5-12 Replacing Power End Bearings................................................................................................ 5-13 Servicing the Wrist Pin Bearings 5-14 Fastener Torque Requirements 5-14 Recommended Lubricants 5-15 Water Pump Motor Repair 5-15 Water Injection Hydraulic Control Valve Repair........................................................................ 5-15 Water Pump Drive Coupling ..................................................................................................... 5-15 Level and Flow Transducer 5-15 Water Pump Motor ........................................................................................................................5-16 Char-Lynn® Hydraulic Motor Manual – 'H' Series 5-16 Tools Required for Disassembly and Reassembly 5-17 Shaft Seal Repair ..................................................................................................................... 5-18 Notes ..............................................................................................................................................5-21 BI620406
Int-10 SKF Introduction Contents Section 6 - Mast / Rotary Drive / Pipe Rack....................................6-1 Section 6 Contents .........................................................................................................................6-3 Mast Weldment................................................................................................................................6-5 Mast Repair 6-5 Weld Inspection Schedule .............................................................................................................6-6 Inspection Mast 6-6 Mast Assembly ................................................................................................................................6-7 Mast Assembly 12m 6-7 Mast Pivot Caps 6-8 Mast Elevate Cylinders 6-8 Angle Drilling 6-9 Feed Cylinders ..............................................................................................................................6-10 SKF 12 Feed System 6-10 Feed Cylinder – Removal 6-11 SKF-12 Feed Cylinder 6-12 Repair 6-13 Installation ................................................................................................................................ 6-13 Hoist / Pulldown Cable .................................................................................................................6-14 Auto Tensioning – Operating Principle ..................................................................................... 6-15 Auto Tensioning – Cable Removal, Adjustment and Installation .............................................. 6-15 Rope Tensioning Circuit ........................................................................................................... 6-17 Wire Rope ................................................................................................................................ 6-19 Sleave Rollers .......................................................................................................................... 6-19 Rotary Head Guide Alignment .....................................................................................................6-20 Alignment Procedure 6-20 Rotary Drive Assembly .................................................................................................................6-21 Rotary Drive Assembly 6-21 Rotary Drive – Removal from Mast 6-22 Rotary Drive – Installation 6-22 Rotary Drive Gearbox ...................................................................................................................6-23 Single Motor Rotary Drive Gearbox 6-23 Air Swivel (Dual Seal Style) 6-25 Service 6-25 Rotary Drive Motor – Repair 6-26 Top Mast Drive Transmission TM2132-4 Manual 6-27 Preface...............................................................................................................................6-28 General Working Instructions.............................................................................................6-29 Work Safety .......................................................................................................................6-30 Symbol Explanation ...........................................................................................................6-30 Conversion Table ...............................................................................................................6-31 Torque Limit Table Grade 5 UNC .......................................................................................6-32 Torque Limit Table Grade 5 UNF .......................................................................................6-33 Torque Limit Table Grade 8 UNC .......................................................................................6-34 Torque Limit Table Grade 8 UNF .......................................................................................6-35 Inscription of the Model Identification Plate .......................................................................6-36 BI620406
SKF Introduction Int-11 Contents Disassembly Transmission ................................................................................................6-37 Assembly Transmission .....................................................................................................6-44 Rotary Drive Motor .......................................................................................................................6-62 Rotary Drive Motor .............................................................................................................6-62 Winch Assembly ...........................................................................................................................6-63 Precautions on the use of Winches .......................................................................................... 6-63 Wire Rope 6-63 Wedge Socket 6-65 Grooved Drums ........................................................................................................................ 6-65 Plain (Smooth) Drums 6-66 Drums - Multiple Layers 6-66 Winch Assembly Service .......................................................................................................... 6-67 BG8A and BG8B Hydraulic Winch Manual 6-68 Forward ..............................................................................................................................6-69 Explanation of Model Number ...........................................................................................6-69 Theory of Operation ...........................................................................................................6-70 Winch Installation ...............................................................................................................6-72 Wire Rope Installation ........................................................................................................6-73 Preventative Maintenance .................................................................................................6-74 071 Motor ...........................................................................................................................6-75 Troubleshooting .................................................................................................................6-76 Disassembly of Winch........................................................................................................6-80 Planetary Carrier Service ...................................................................................................6-82 Motor Support Brake Cylinder Service ..............................................................................6-84 Brake Clutch Service .........................................................................................................6-88 Winch Assembly ................................................................................................................6-90 Brake Valve Service ...........................................................................................................6-92 Reversing Direction of Drum Rotation ...............................................................................6-94 Recommended Fastener Torque .......................................................................................6-95 Metric Conversion Table ....................................................................................................6-96 H.O.B.O Wrench ............................................................................................................................6-97 Tong Dies 6-98 Deck Wrench .................................................................................................................................6-99 Pipe Positioner ............................................................................................................................6-100 Pipe Positioner .......................................................................................................................6-100 Carousel Pipe Rack ....................................................................................................................6-101 If Pipe Rack Does Not Rotate 6-101 Chain Drive – Adjust / Replace............................................................................................... 6-101 Pipe Rack Bearings - Replace 6-102 Carousel Top Tube Bearing – Replace 6-103 Carousel Lower Bearing – Replace........................................................................................ 6-105 Carousel Pivot Support Upper Bearing – Replace 6-107 Carousel Pivot Support Lower Bearing – Replace 6-109 Mid Point Carousel Pivot Support ........................................................................................... 6-110 Carousel Rotate Motor 6-110 Notes .............................................................................................................................................6-111 BI620406
Int-12 SKF Introduction Contents Section 7 - Hydraulic Systems ........................................................7-1 Section 7 Contents .........................................................................................................................7-3 Hydraulic Symbols .........................................................................................................................7-7 Hydraulic Tank ................................................................................................................................7-9 Hydraulic Tank 7-10 Hydraulic System 7-10 Pressure Setting Sequence ....................................................................................................7-11 Pressure Setting Sequence 7-11 Hydraulic System 7-11 Main Return and Case Drain Filter ..............................................................................................7-12 Routine Maintenance ............................................................................................................... 7-13 Changing Filter Elements ......................................................................................................... 7-13 Main Hydraulic Pumps .................................................................................................................7-14 Hydraulic Pump Identification ................................................................................................... 7-14 Right Track / Pulldown, Left Track / Rotation Pumps ...............................................................7-15 Hydraulic Piston Pumps – Removal and Replacement 7-15 Main Pumps 7-16 AA4VG 125 Hydraulic Pump EP2 Control 7-16 AA4VG EP Controller 7-18 Technical Data 7-19 EP (24V DC) Control 7-21 Schematic Drawing – Standard Model 7-21 Technical Data 7-22 Port Locations 7-24 Connections 7-24 Main Pump Adjustments 7-25 Set Charge Pressure 450psi (31bar) 7-27 Set Pressure Override 5000psi (38bar) 7-27 Set Pressure Override (P.O.R) – 5000psi (345bar) 7-28 Mechanical Zero Position ......................................................................................................... 7-29 Hydraulic Piston Pumps – Maintenance .....................................................................................7-30 Hydraulic Centreing .................................................................................................................. 7-30 Removal and Inspection of Charge Pump................................................................................ 7-31 Hydraulic Piston Pumps – Troubleshooting ..............................................................................7-32 Removal and Installation of Shaft Seal .................................................................................... 7-32 Routine Maintenance 7-33 Charge Circuit ...............................................................................................................................7-38 Double Gear Pump – Right Charge and Water Injection.......................................................... 7-38 Charge Circuit Schematic 7-39 Routine Maintenance 7-41 Changing Filter Elements 7-41 Loop Filters ...................................................................................................................................7-42 Loop Filters 7-42 Routine Maintenance 7-45 Changing Filter Elements 7-45 BI620406
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
