Technical Manual
© Bucyrus All Rights Reserved
R
BI620441
BUCYRUS
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Think Terex, Think Integrity SKSS-16 Infinity Blasthole Drill
No.1S67T74 Service Manual SERVICE MANUAL PART NO. 91-A11-456 August 2008, Version 1 BI620441
Serial
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-2 SKSS Introduction Safety Information BI620441
Parts Ordering and 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 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
SKSS Introduction Int-3
Product Support BI620441
Parts Ordering and
iv SKSS Introduction 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 ................................................................................................................2-5 Warning Decals ...............................................................................................................................2-9 Operators Controls and Indicators .............................................................................................2-12 Right Hand Control Panel ............................................................................................................2-13 Control Panels ..........................................................................................................................2-13 Instrument Panel and Circuit Breakers ......................................................................................2-14 Instrument Panel ......................................................................................................................2-15 Circuit Breakers ........................................................................................................................2-15 Light Switches ..........................................................................................................................2-15 System Pressure Gauge Panel ....................................................................................................2-16 Left Hand Control Panel ...............................................................................................................2-18 Foot Control Pedals ......................................................................................................................2-22 Cab Foot Controls ....................................................................................................................2-22 Thread Grease Switch..............................................................................................................2-22 Pipe Safety Arm Override Switch .............................................................................................2-22 Air Conditioner ..............................................................................................................................2-23 T8 Series Split System Air Conditioning Manual Contents.......................................................2-23 Section 1.0 Technical Data and Control Settings .....................................................................2-24 Section 2.0 Installation and Commissioning.............................................................................2-26 Section 3.0 Routine Maintenance Procedures .........................................................................2-30 Section 4.0 Fault Diagnosis......................................................................................................2-31 Section 5.0 Basic Spare Parts Listing ......................................................................................2-40 Section 6.0 Reference Drawings ..............................................................................................2-42 Zexel DK-32 Compressor .........................................................................................................2-46 Performance Curve ..................................................................................................................2-47 Notes ..............................................................................................................................................2-48 BI620441
SKSS Introduction v Contents Section 3 - Main Frame / Crawlers ..................................................3-1 Section 3 Contents .........................................................................................................................3-3 Levelling Jacks ...............................................................................................................................3-5 Levelling Jacks ...........................................................................................................................3-6 Limit Switch ................................................................................................................................3-6 Levelling Jack Cylinders .............................................................................................................3-6 Mast Elevating Cylinders ...............................................................................................................3-7 Mast Elevating Cylinders ............................................................................................................3-7 Remove ......................................................................................................................................3-9 Repair .........................................................................................................................................3-9 Replace ......................................................................................................................................3-9 Crawler Assembly .........................................................................................................................3-10 Crawler Component Repair .......................................................................................................3-11 Metric Bolt Torque Specifications ...............................................................................................3-12 Track Tension Adjustment ...........................................................................................................3-13 Before Operating the Machine .................................................................................................3-13 General Maintenance ...............................................................................................................3-13 Idler Unit Description ................................................................................................................3-15 Hydraulic Tensioner .....................................................................................................................3-16 Hydraulic Tensioner ..................................................................................................................3-16 Repair .......................................................................................................................................3-16 Nitrogen Tensioner .......................................................................................................................3-17 Nitrogen Tensioner ...................................................................................................................3-17 Nitrogen Tensioner – Filling Instructions ..................................................................................3-18 Nitrogen Tensioner – Pressure Check ......................................................................................3-19 Nitrogen Tensioner – Pressure Release ...................................................................................3-19 Track Chain – Separate ................................................................................................................3-20 Track Chain – Separate............................................................................................................3-20 Track Chain – Repair ....................................................................................................................3-21 Track Link – Description ...........................................................................................................3-21 Track Link – Repair and Replace .............................................................................................3-21 Track Shoes Installation...............................................................................................................3-23 Track Link Position ...................................................................................................................3-23 Track Shoe – Mounting to Track Chain ....................................................................................3-23 Track Shoe Bolt Torque (Direct Torque Method) .......................................................................3-24 Bolt Torque – KN111 .................................................................................................................3-24 Track Shoe Bolt Torque (Torque Turn Method) .........................................................................3-25 Bolt Torque – KN111 .................................................................................................................3-25 Final Drive .....................................................................................................................................3-26 Removal from Track Frame ......................................................................................................3-26 F130 Final Drive Assembly .......................................................................................................3-27 Parts List ..................................................................................................................................3-28 F130 Final Drive .......................................................................................................................3-29 General Description..................................................................................................................3-29 General Recommendations for Disassembly and Assembly Operations .................................3-30 Safety Precautions ...................................................................................................................3-31 BI620441
vi SKSS Introduction Contents Service Information ..................................................................................................................3-32 Tightening Torques ...................................................................................................................3-33 Lubrication / Greasing: Grades and Application Range ...........................................................3-33 Motor Type A2FE125 – A2FE160 .............................................................................................3-35 Planetary Gears F130/206-A....................................................................................................3-36 Brake ........................................................................................................................................3-43 Bearings ...................................................................................................................................3-47 Trouble Shooting ......................................................................................................................3-50 Special Tools ............................................................................................................................3-50 Installation into Track Frame ....................................................................................................3-51 Idler Unit Assembly ......................................................................................................................3-52 Idler Unit – Assembly................................................................................................................3-53 Idler Unit Removal ........................................................................................................................3-55 Idler Unit – Removal .................................................................................................................3-55 Track and Support Rollers ...........................................................................................................3-56 General Description..................................................................................................................3-56 Track Roller – Removal and Disassembly................................................................................3-57 Support Roller – Removal and Disassembly ............................................................................3-57 Track and Support Roller – Assembly ......................................................................................3-58 Track and Support Roller – Test and Install..............................................................................3-59 Auxiliary Crane .............................................................................................................................3-61 Hydraulic Crane (Auxiliary Crane) ............................................................................................3-61 Maintenance .............................................................................................................................3-62 Checking of Worm Gear ...........................................................................................................3-62 Weld Inspection Schedule ...........................................................................................................3-63 Main Frame ..............................................................................................................................3-63 Notes ..............................................................................................................................................3-64 Section 4 - Engine / Drive Train / Compressor...............................4-1 Section 4 Contents .........................................................................................................................4-3 Power Group Locator .....................................................................................................................4-6 Cummins Engine ............................................................................................................................4-7 Engine Fuel System ...................................................................................................................4-8 Construction ...............................................................................................................................4-9 Electric Fuel Supply Pumps .......................................................................................................4-9 Combo Fuel Filter Head and Pump Manifold ...........................................................................4-10 FS1006 Fuel Filter with Water Separator .................................................................................4-10 Fuel Manifold with Integrated FSO Valve ..................................................................................4-11 Fuel Connections ......................................................................................................................4-11 Pre-filters ..................................................................................................................................4-12 Wiring with EFS Power Relay ..................................................................................................4-12 Pressure and Temperature Sensors .........................................................................................4-12 Operation ..................................................................................................................................4-13 QST30 Electric Fuel Supply System ........................................................................................4-14 Oil Reserve Systems ................................................................................................................4-16 Engine Oil Reserve System (Basic Circuit) ..............................................................................4-16 LED Monitor Readings .............................................................................................................4-17 BI620441
SKSS Introduction vii Contents Adjustment of Running Oil Level ..............................................................................................4-17 Wiring Diagram – Oil Reserve Basic Circuit .............................................................................4-18 Oil Pressure Switch ..................................................................................................................4-18 Oil Reserve System ..................................................................................................................4-18 Troubleshooting ........................................................................................................................4-19 Maintenance .............................................................................................................................4-19 Engine and Compressor Air Cleaner ..........................................................................................4-20 Engine and Compressor Air Cleaner Service ...........................................................................4-21 Compressor Assembly .................................................................................................................4-24 Flexible Drive Coupling ................................................................................................................4-25 Flexible Drive Coupling Service ...............................................................................................4-25 Pump Drive ....................................................................................................................................4-27 Pump Identification ...................................................................................................................4-27 Pump Drive Assembly – Removal and Replacement ...............................................................4-28 Pump Drive Gearbox ....................................................................................................................4-29 Pump Drive Gearbox Repair ....................................................................................................4-30 3" Input Shaft Assembly ...........................................................................................................4-32 Hydraulic Pumps ..........................................................................................................................4-33 Hydraulic Pumps – Removal and Replacement .......................................................................4-33 Compressor Installation ...............................................................................................................4-34 Compressor Installation............................................................................................................4-34 Compressor Drive Coupling .....................................................................................................4-35 Compressor Drive Coupling - Removal and Replacement.......................................................4-36 Compressor Unit – Removal ....................................................................................................4-37 Compressor Shaft Seal ................................................................................................................4-39 High Pressure Compressor .........................................................................................................4-43 Safety .......................................................................................................................................4-43 Description ...............................................................................................................................4-46 Compressed Air Functions .......................................................................................................4-46 Compressor Oil Circuit ................................................................................................................4-50 Compressor Oil Circuit – 1475cfm @ 500psi ...........................................................................4-50 Compressor Condensation Table ...............................................................................................4-53 Compressor Air Circuit ................................................................................................................4-54 Compressor Air Circuits - 1475cfm @ 500psi ..........................................................................4-54 Compressor Air Circuit Diagram Legend ..................................................................................4-55 Compressor Functional Description ...........................................................................................4-69 Compressor Operation .................................................................................................................4-72 Operation ..................................................................................................................................4-72 Compressor Maintenance ............................................................................................................4-75 General Maintenance ...............................................................................................................4-75 Interstage Tube ........................................................................................................................4-77 Discharge Check Valve ............................................................................................................4-78 Separator/Receiver Tank ..........................................................................................................4-79 Scavenge Line..........................................................................................................................4-81 Compressor Discharge Temperature Switches, Senders and Gauges ....................................4-82 Minimum Pressure Valve ..........................................................................................................4-83 BI620441
viii SKSS Introduction Contents Minimum Pressure / Check Valve Maintenance .......................................................................4-83 Thermal Bypass Valve ..............................................................................................................4-84 Thermal Bypass Valve Maintenance ........................................................................................4-85 Compressor Fluid Filter ............................................................................................................4-86 Changing Filter Elements .........................................................................................................4-86 Fluid Stop Valve .......................................................................................................................4-88 Inlet Valve .................................................................................................................................4-90 Relieving Regulators ................................................................................................................4-92 Reducing Regulators ................................................................................................................4-95 Reducing Regulator Maintenance ............................................................................................4-95 System Blowdown Valve ..........................................................................................................4-97 Running Blowdown Valve .........................................................................................................4-98 Running Blowdown Maintenance .............................................................................................4-99 Moisture Separator Maintenance ...........................................................................................4-100 System Air Dryer ....................................................................................................................4-101 Airodyn Compressed Air Drain Trap Installation.....................................................................4-102 Airodyn Compressed Air Drain Trap Operation ......................................................................4-102 Airodyn Compressed Air Drain Trap Maintenance .................................................................4-103 Auxiliary Regulator .................................................................................................................4-104 Auxiliary Regulator Maintenance............................................................................................4-106 Troubleshooting ......................................................................................................................4-108 Coolers Locator ...........................................................................................................................4-111 Coolers Locator .......................................................................................................................4-111 Compressor Oil Cooler Assembly ..............................................................................................4-112 Compressor Oil Cooler ............................................................................................................4-112 Hydraulic Oil / Radiator Cooler Assembly .................................................................................4-113 Hydraulic Oil / Radiator Cooler Assembly ...............................................................................4-113 Coolers Maintenance ...................................................................................................................4-114 Compressor Oil / Hydraulic Oil Cooler Service Manual ...........................................................4-115 Standard Parts – High Pressure Oil Coolers ...........................................................................4-115 Repair Instructions ..................................................................................................................4-116 Radiator Cooler Service Manual ................................................................................................4-120 Standard Parts of Typical MESABI Radiator Core .................................................................4-120 Cleaning .................................................................................................................................4-121 Tube Removal ........................................................................................................................4-121 Seal Installation ......................................................................................................................4-122 Tube Installation .....................................................................................................................4-123 Notes ............................................................................................................................................4-125 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 Water Tanks................................................................................................................................5-6 Water Tank Top up Solenoid Valve .............................................................................................5-7 BI620441
SKSS Introduction ix Contents Water Injection Relief Valve........................................................................................................5-9 Water Injection Control .............................................................................................................5-10 Water and Foam Injection Controller .........................................................................................5-11 Water Injection Basic Circuit.....................................................................................................5-14 Water Pump ...................................................................................................................................5-15 Pump Specifications .................................................................................................................5-15 Servicing Instructions ...............................................................................................................5-15 Parts List ..................................................................................................................................5-16 Replacing Piston Cup Seals .....................................................................................................5-17 Replacing Suction and Discharge Valves .................................................................................5-18 Replacing Power End Bearings................................................................................................5-19 Servicing the Wrist Pin Bearings ..............................................................................................5-20 Fastener Torque Requirements ................................................................................................5-20 Recommended Lubricants .......................................................................................................5-21 Water Pump Motor Repair ........................................................................................................5-21 Water Injection Hydraulic Control Valve Repair........................................................................5-21 Water Pump Drive Coupling .....................................................................................................5-21 Level and Flow Transducer ......................................................................................................5-21 High Pressure Cleaner .................................................................................................................5-22 High Pressure Washdown (Motor and Pump) ..........................................................................5-22 Parts List ..................................................................................................................................5-23 Water Injection Valve ....................................................................................................................5-28 Water Injection Ball Valve Assembly ........................................................................................5-28 Water Injection Ball Valve .........................................................................................................5-28 Water Injection Ball Valve Assembly ........................................................................................5-29 Actuator – Installation Operation and Maintenance Manual.....................................................5-30 Air Connections ........................................................................................................................5-30 Disassembly .............................................................................................................................5-31 Removing Endcaps Type ES ....................................................................................................5-32 Removing Pistons/Spindle .......................................................................................................5-33 Reassembly Guide Band and Shaft .........................................................................................5-33 Reassembly Pistons .................................................................................................................5-34 Reassembly End Caps Single Acting Actuators .......................................................................5-34 Reassembly Of Spring Clip and Insert .....................................................................................5-35 Parts List ..................................................................................................................................5-37 Foam Injection System .................................................................................................................5-38 Foam Injection System Manual ................................................................................................5-38 Routine Maintenance ...............................................................................................................5-41 Maintenance Schedule .............................................................................................................5-45 Fault Finding .............................................................................................................................5-48 Notes ..............................................................................................................................................5-52 Section 6 - Mast / Rotary Drive / Pipe Rack....................................6-1 Section 6 Contents .........................................................................................................................6-3 Mast Weldment................................................................................................................................6-5 Mast Repair ................................................................................................................................6-5 BI620441
x SKSS Introduction Contents Weld Inspection Schedule .............................................................................................................6-6 Inspection Mast ..........................................................................................................................6-6 Mast Assembly ................................................................................................................................6-7 Mast Assembly 16m ...................................................................................................................6-7 Mast Pivot ...................................................................................................................................6-8 Mast Locks ...............................................................................................................................6-10 Feed Cylinders ..............................................................................................................................6-12 Feed Cylinder – Removal .........................................................................................................6-14 Feed Cylinder Assembly...........................................................................................................6-16 Repair .......................................................................................................................................6-17 Installation ................................................................................................................................6-17 Hoist / Pulldown Cable Adjustment with Auto Tension.............................................................6-18 Hoist / Pulldown Cable Adjustment ..........................................................................................6-20 Hoist / Pulldown Cable Replacement .......................................................................................6-23 Rotary Drive Assembly .................................................................................................................6-24 Rotary Head Guide Alignment ..................................................................................................6-25 Rotary Head – Drive System ....................................................................................................6-26 Rotary Drive – Removal from Mast ..........................................................................................6-27 Rotary Drive – Installation ........................................................................................................6-27 Rotary Drive Gearbox ...................................................................................................................6-28 Rotary Drive Gearbox – Item Listing ........................................................................................6-29 Rotary Head Bull Shaft Bearing Nut .........................................................................................6-29 Rotary Drive Gearbox – Repair ................................................................................................6-30 Air Swivel ..................................................................................................................................6-31 Winch Assembly ...........................................................................................................................6-32 Precautions on the Use of Winches .........................................................................................6-32 Wire Rope ................................................................................................................................6-32 Wedge Socket ..........................................................................................................................6-34 Grooved Drums ........................................................................................................................6-34 Plain (Smooth) Drums ..............................................................................................................6-35 Drums – Multiple Layers ...........................................................................................................6-35 Winch Assembly Service ..........................................................................................................6-36 BG8A and BG8B Hydraulic Winch Service Manual..................................................................6-37 Forward ....................................................................................................................................6-38 General Safety Recommendations ..........................................................................................6-39 Theory of Operation .................................................................................................................6-40 Winch Installation .....................................................................................................................6-42 Wire Rope Installation ..............................................................................................................6-43 Preventative Maintenance ........................................................................................................6-44 Trouble Shooting ......................................................................................................................6-46 Disassembly of Winch ..............................................................................................................6-50 Planetary Carrier Service .........................................................................................................6-52 Motor Support – Brake Cylinder Service ..................................................................................6-54 Brake Clutch Service ................................................................................................................6-58 Winch Assembly .......................................................................................................................6-60 Brake Valve Service .................................................................................................................6-62 Reversing Direction of Drum Rotation ......................................................................................6-64 BI620441
SKSS Introduction xi Contents Deck Wrench .................................................................................................................................6-67 HOBO Wrench ...............................................................................................................................6-68 Breakout System – HOBO .......................................................................................................6-69 Hydraulic Operated Bit Basket – HOBB ...................................................................................6-69 Pipe Safety Arm........................................................................................................................6-69 Pipe Positioner ..............................................................................................................................6-70 Carousel Pipe Rack ......................................................................................................................6-71 Major Components ...................................................................................................................6-71 Rod Handling – Carousel Indexing...........................................................................................6-72 Carousel Pipe Rack Assembly .................................................................................................6-73 General Information..................................................................................................................6-74 Pipe Rack Bearings – Removal................................................................................................6-74 Pipe Rack Componetns – Inspection .......................................................................................6-77 Pipe Rack – Assembly and Installation ....................................................................................6-78 Pipe Rack Roller – Remove and Replace ................................................................................6-79 Pipe Rack Roller – Disassembly and Assembly .......................................................................6-80 Notes ..............................................................................................................................................6-82 Section 7 - Hydraulic Systems ........................................................7-1 Section 7 Contents .........................................................................................................................7-3 Hydraulic Symbols .........................................................................................................................7-6 Pressure Setting Sequence ...........................................................................................................7-8 Pressure Setting Sequence........................................................................................................7-8 Hydraulic Tank ..............................................................................................................................7-10 Hydraulic Tank ..........................................................................................................................7-10 Return Hydraulic Filters .............................................................................................................7-11 Main Return and Case Drain Filters ............................................................................................7-12 Routine Maintenance ...............................................................................................................7-13 Changing Filter Elements .........................................................................................................7-13 Main Hydraulic Pumps .................................................................................................................7-14 Pump Identification ...................................................................................................................7-14 Right Track, Left Track / Rotation Pumps ..................................................................................7-15 Hydraulic Piston Pumps – Removal and Replacement ............................................................7-15 Main Pumps .............................................................................................................................7-16 AA4VG180 Hydraulic Pump EP2 Control.................................................................................7-16 AA4VG EP Controller ...............................................................................................................7-18 Technical Data ..........................................................................................................................7-19 EP (24V DC) Control ................................................................................................................7-21 Schematic Drawings – Standard Model ...................................................................................7-21 Technical Data ..........................................................................................................................7-22 Port Locations ..........................................................................................................................7-24 Connections .............................................................................................................................7-24 Main Pump Adjustments...........................................................................................................7-25 Change Pressure, High Pressure, P.O.R. and Zero Position Settings .....................................7-26 Set Change Pressure – 450psi (31bar) ....................................................................................7-27 Set Crossover Relief (High Pressure) – 5500psi (380bar) .......................................................7-27 Set Pressure Override (P.O.R.) – 5000psi (345bar) .................................................................7-28 BI620441
xii SKSS Introduction Contents Mechanical Zero Position .........................................................................................................7-29 Hydraulic Centreing ..................................................................................................................7-30 Removal and Inspection of Charge Pump................................................................................7-31 Removal and Installation of Shaft Seal ....................................................................................7-32 Routine Maintenance ...............................................................................................................7-33 Maintenance .............................................................................................................................7-34 Charge Filter ..................................................................................................................................7-36 Routine Maintenance ...............................................................................................................7-36 Changing Filter Elements .........................................................................................................7-37 Main Pumps Circuit ......................................................................................................................7-38 Main Pumps Circuit ..................................................................................................................7-38 Rotation/Tram Motor Circuit .....................................................................................................7-39 Loop Filters ...................................................................................................................................7-40 Routine Maintenance ...............................................................................................................7-40 Changing Filter Elements .........................................................................................................7-43 Rotation Circuit .............................................................................................................................7-44 Rotation Circuit .........................................................................................................................7-45 Rotary Drive Gearbox Motor ........................................................................................................7-46 Rotary Drive Gearbox Motor – Test and Repair .......................................................................7-46 Shaft Seal Replacement...........................................................................................................7-47 Trouble Shooting ......................................................................................................................7-49 Tram Circuit ...................................................................................................................................7-51 Tram Circuit ..............................................................................................................................7-51 Feed and Auxiliary Pump Circuit .................................................................................................7-53 Hydraulic Piston Pumps – Removal and Replacement ............................................................7-53 Feed and Auxiliary Functions Pump .........................................................................................7-56 Repair Instructions ...................................................................................................................7-57 Pump Replacement – Start Up.................................................................................................7-58 Hydraulic Systems ........................................................................................................................7-60 Auxiliary and Feed Circuits .......................................................................................................7-60 Main Control Valves ......................................................................................................................7-61 Valve Stand Assembly ..............................................................................................................7-61 Pilot Control Manifold...................................................................................................................7-62 Pilot Control Manifold ...............................................................................................................7-62 Electro Proportional Relief Valve ..............................................................................................7-70 Proportional Valve Set-up .........................................................................................................7-71 Proportional Pulldown ..............................................................................................................7-71 OEM Electro Proportional Mast Raise /Jack Valve ..................................................................7-72 Technical Data ..........................................................................................................................7-72 Hoist and Pulldown Control .........................................................................................................7-73 M4-22 Valve .............................................................................................................................7-75 M4-22 Valve Schematic ............................................................................................................7-76 Holdback Control ..........................................................................................................................7-80 Jack Control and Mast Elevating Circuit ....................................................................................7-81 OEM Controllers / EP Levers ...................................................................................................7-82 Jack Control and Mast Elevating Circuit...................................................................................7-83 BI620441
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