Parts Ordering and Product Support
Use only genuine Bucyrus parts in the maintenance, rebuild, or repair, of Bucyrus machines. Bucyrus 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 Bucyrus's furnished manuals, or other written instructions, or which are operated with other than genuine Bucyrus 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 Bucyrus makes no other warranty, express or implied. Products and services listed may be trademarks, service marks or trade names of Bucyrus International, Inc and/or its subsidiaries in the USA and other countries. All rights are reserved. Bucyrus is a registered trademark of Bucyrus International, Inc in the USA and many other countries. Copyright (or ©) 2007 Bucyrus International, Inc.
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 Bucyrus 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.
Bucyrus International, Inc.® March, 11 Version 1 Int-3 SKSS-13 Introduction
MAILING ADDRESSFOR PARTS ORDER ENTRYSHIPPING ADDRESS Bucyrus WA Telephone 1300 883 677 Bucyrus 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 Perth Level 8, 369 Ann Street20 Kullara Close10-12 Corporate Drive2 Reid Road Brisbane, QLD 4000 Beresfield, NSW 2322 Mackay, QLD 4740Perth International Airport, WA 6105 Ph: (07) 3009 3600Ph: (02) 4914 7000Ph: (07) 4952 0600Ph (08) 9373 6000 Fax: (07) 3009 3699Fax: (02) 4914 7007Fax: (07) 4952 0666Fax (08) 9373 6173 © Bucyrus International, Inc 2007 BI620423
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:
Bucyrus International, Inc.® SKSS-13 Introduction Int-4 March, 11 Version 1
Safety Information
BI620423
Bucyrus International, Inc.® March, 11 Version 1 Int-5 SKSS-13 Introduction Contents Section 1 – Safety ............................................................................. 1-1 Section 1 Contents .........................................................................................................................1-3 Safety ...............................................................................................................................................1-5 Overview of Potential Hazards ...................................................................................................1-5 Personal Protective Equipment ..................................................................................................1-5 Noise ..........................................................................................................................................1-5 Electrical Contact .......................................................................................................................1-5 Contaminated Air ........................................................................................................................1-6 Moving and Rotating Parts .........................................................................................................1-7 High Pressure Air or Fluid ..........................................................................................................1-7 Before Operation ........................................................................................................................1-7 During Operation ........................................................................................................................1-8 Maintenance .............................................................................................................................1-10 Equipment Transfer ..................................................................................................................1-10 Safety Locator ...........................................................................................................................1-11 Notes ..............................................................................................................................................1-14 Section 2 - Operator's Cab / Controls ............................................. 2-1 Section 2 Contents .........................................................................................................................2-3 Graphic Symbol Legend ................................................................................................................2-5 Graphic Symbol Legend .............................................................................................................2-5 Warning Decals ...............................................................................................................................2-9 Warning Decals ..........................................................................................................................2-9 Operator Control and Instrument Panels ...................................................................................2-12 Control Panels ..........................................................................................................................2-12 Right Hand Control Panel.........................................................................................................2-12 Instrument Panel ......................................................................................................................2-14 Circuit Breakers ........................................................................................................................2-15 Light Switches ..........................................................................................................................2-15 System Pressure Gauge Panel ................................................................................................2-16 Left Hand Control Panels .........................................................................................................2-18 Cab Foot Controls ....................................................................................................................2-22 Thread Grease Switch..............................................................................................................2-22 Pipe Safety Arm Override Switch .............................................................................................2-22 Machine Stability ..........................................................................................................................2-23 Tramming Procedure ................................................................................................................2-23 Track Adjustments ....................................................................................................................2-23 New Machine Procedure ..........................................................................................................2-24 General Maintenance Checks While Tramming .......................................................................2-24 Roller Locations........................................................................................................................2-25 Temperature and Condition Record Chart for Walking .............................................................2-26 Propelling the Machine .............................................................................................................2-27 Stability Limits ..........................................................................................................................2-29 SKF Transient Stability Limits...................................................................................................2-30 Cab Heater .....................................................................................................................................2-31 Cab Heater Fault Isolation........................................................................................................2-31 BI620423
Bucyrus International, Inc.® SKSS-13 Introduction Int-6 March, 11 Version 1 Contents Air Conditioner ..............................................................................................................................2-32 T8 Series Split System Air Conditioning ...................................................................................2-32 Section 1.0 Technical Data and Control Settings .....................................................................2-33 Section 2.0 Installation and Commissioning.............................................................................2-35 Section 3.0 Routine Maintenance Procedures .........................................................................2-39 Section 4.0 Fault Diagnosis......................................................................................................2-40 Section 5.0 Reference Drawings ..............................................................................................2-49 Notes ..............................................................................................................................................2-55 Section 3 - Main Frame / Crawlers .................................................. 3-1 Section 3 Contents .........................................................................................................................3-3 Main Frame Repair – General ........................................................................................................3-5 Main Frame Repair .....................................................................................................................3-5 Weld Inspection Schedule .............................................................................................................3-6 Main Frame ................................................................................................................................3-6 Levelling Jacks ...............................................................................................................................3-7 Levelling Jacks Cylinder .............................................................................................................3-7 Levelling Jacks ...........................................................................................................................3-8 Limit Switch ................................................................................................................................3-8 Levelling Jack Cylinders .............................................................................................................3-8 Mast Elevating Cylinders ...............................................................................................................3-9 Mast Elevating Cylinders ............................................................................................................3-9 Internal Counterbalance Valve .................................................................................................3-10 Crawler Assembly .........................................................................................................................3-12 Crawler Assembly .....................................................................................................................3-12 Parts List ..................................................................................................................................3-13 Crawler Component Repair ......................................................................................................3-13 Tramming.......................................................................................................................................3-14 Maintenance Checks for Tramming for SK Series Drills ..........................................................3-14 Track Adjustments ....................................................................................................................3-14 New Machine Procedure ..........................................................................................................3-15 General Maintenance Checks While Tramming .......................................................................3-15 Roller Locations........................................................................................................................3-16 Temperature and Condition Record Chart for Walking .............................................................3-17 Metric Bolt Torque Specifications ...............................................................................................3-18 Metric Bolt Torque Specifications .............................................................................................3-18 Track Tension Adjustment ...........................................................................................................3-19 Before Operating the Machine .................................................................................................3-19 General Maintenance ...............................................................................................................3-19 Track Assembly ........................................................................................................................3-20 Idler Unit Description ................................................................................................................3-21 Hydraulic Tensioner ..................................................................................................................3-22 Nitrogen Tensioner ...................................................................................................................3-23 Track Chain ...................................................................................................................................3-26 Track Chain ..............................................................................................................................3-26 BI620423
Bucyrus International, Inc.® March, 11 Version 1 Int-7 SKSS-13 Introduction Contents Track Shoes Installation...............................................................................................................3-29 Track Link Position ...................................................................................................................3-29 Track Shoe – Mounting to Track Chain ....................................................................................3-29 Track Shoe Bolt Torque (Direct Torque Method) .......................................................................3-31 Bolt Torque KN111 ....................................................................................................................3-31 Track Shoe Bolt Torque (Torque Turn Method) .........................................................................3-32 Bolt Torque KN111 ....................................................................................................................3-32 Track Chain and Shoe Installation ..............................................................................................3-33 Track Chain with Shoes............................................................................................................3-33 Final Drive Unit .............................................................................................................................3-35 General Description..................................................................................................................3-35 Removal from Track Frame ......................................................................................................3-36 Installation into Track Frame ....................................................................................................3-37 Final Drive Maintenance ...........................................................................................................3-38 Final Drive Oil ...........................................................................................................................3-39 F130 Final Drive Assembly.......................................................................................................3-40 Parts List ..................................................................................................................................3-41 F130 Final Drive .......................................................................................................................3-42 General Description..................................................................................................................3-42 Service Information ..................................................................................................................3-43 Tightening Torques ...................................................................................................................3-44 Lubrication / Greasing – Grades and Application Range .........................................................3-44 Planetary Gears F130/206-A....................................................................................................3-45 Troubleshooting ........................................................................................................................3-46 Special Tools ............................................................................................................................3-46 Idler Unit ........................................................................................................................................3-47 Idler Unit – Assembly................................................................................................................3-47 Idler Unit – Removal .................................................................................................................3-50 Track and Support Rollers ...........................................................................................................3-51 Track Roller Assembly ..............................................................................................................3-51 General Description..................................................................................................................3-51 Track Roller – Removal and Disassembly................................................................................3-52 Support Roller – Removal and Disassembly ............................................................................3-52 Track and Support Roller – Assembly ......................................................................................3-53 Track and Support Roller – Test and Install..............................................................................3-54 Track and Sprocket Inspection....................................................................................................3-56 Track Inspection and Wear Limit Guide ...................................................................................3-56 Sprocket Wear Patterns ...........................................................................................................3-60 Auxiliary Crane .............................................................................................................................3-66 Hydraulic Crane – Rear Deck Crane Palfinger PC1500...........................................................3-66 Rear Deck Crane Palfinger PC1500 Service information.........................................................3-67 Checking Bolted Connections ..................................................................................................3-67 Maintenance Chart ...................................................................................................................3-68 Lubrication ................................................................................................................................3-70 Hydraulic Fluids ........................................................................................................................3-73 Oil Change / Oil Maintenance ..................................................................................................3-74 BI620423
Bucyrus International, Inc.® SKSS-13 Introduction Int-8 March, 11 Version 1 Contents Cleaning Agents and Equipment ..............................................................................................3-74 Repairing Paint Damage ..........................................................................................................3-75 Removal From Service and Disposal .......................................................................................3-75 Notes ..............................................................................................................................................3-76 Section 4 - Engine / Drive Train / Compressor ............................... 4-1 Section 4 Contents .........................................................................................................................4-3 Power Group Locator .....................................................................................................................4-5 Power Group Locator .................................................................................................................4-5 Cummins Engine ............................................................................................................................4-6 Cummins Engine ........................................................................................................................4-6 QST30 Electric Fuel Supply System ..........................................................................................4-7 Construction ...............................................................................................................................4-8 Electric Fuel Supply Pumps .......................................................................................................4-8 Combo Fuel Filter Head and Pump Manifold .............................................................................4-8 FS1006 Fuel Filter with Water Separator ...................................................................................4-8 Fuel Manifold with Integrated FSO Valve ...................................................................................4-9 Fuel Connections .......................................................................................................................4-9 Pre-filters ....................................................................................................................................4-9 Wiring with EFS Power Relay ..................................................................................................4-10 Pressure and Temperature Sensors .........................................................................................4-10 Operation ...................................................................................................................................4-11 QST30 Electric Fuel Supply System Flow Diagram .................................................................4-12 QST30 Electric Fuel Supply System Detail ..............................................................................4-13 Oil Reserve Systems ................................................................................................................4-14 LED Monitor Readings .............................................................................................................4-15 Adjustment of Running Oil Level ..............................................................................................4-15 Wiring Diagram – Oil Reserve Basic Circuit .............................................................................4-16 Oil Pressure Switch ..................................................................................................................4-16 Oil Reserve System ..................................................................................................................4-16 Troubleshooting ........................................................................................................................4-17 Maintenance .............................................................................................................................4-17 Engine and Compressor Air Cleaners ........................................................................................4-18 Engine and Compressor Air Cleaner Service Assembly ..........................................................4-18 Engine and Compressor Air Cleaner Service ...........................................................................4-19 Flexible Drive Coupling ................................................................................................................4-22 Flexible Drive Coupling Service ...............................................................................................4-22 Pump Drive ....................................................................................................................................4-24 Pump Identification ...................................................................................................................4-24 Pump Drive Assembly – Removal and Replacement ...............................................................4-25 Pump Drive Gearbox ................................................................................................................4-26 Pump Drive Gearbox Repair ....................................................................................................4-27 Pump Drive Gear Box Input Shaft Assembly............................................................................4-28 Hydraulic Pumps ..........................................................................................................................4-30 Hydraulic Pumps – Removal and Replacement .......................................................................4-30 BI620423
Bucyrus International, Inc.® March, 11 Version 1 Int-9 SKSS-13 Introduction Contents Compressor Installation ...............................................................................................................4-31 Compressor Installation............................................................................................................4-31 Compressor Drive Coupling .....................................................................................................4-33 Compressor Alignment .............................................................................................................4-35 Compressor Shaft Seal ................................................................................................................4-36 Compressor Shaft Seal ............................................................................................................4-36 Low Pressure Compressor ..........................................................................................................4-38 Safety .......................................................................................................................................4-38 Description ...............................................................................................................................4-41 Compressed Air Functions .......................................................................................................4-41 Compressor Oil Circuit – 2400cfm @ 100psi ...........................................................................4-45 Compressor Air Circuit – 2400cfm @ 0psi ...............................................................................4-49 Compressor Air Circuit – 2400cfm @ 50psi .............................................................................4-50 Compressor Air Circuit – 2400cfm @ 100psi ...........................................................................4-51 Compressor Air Circuit – 2400cfm @ 60psi .............................................................................4-52 Compressor Functional Description .........................................................................................4-53 Operation ..................................................................................................................................4-55 Compressor Maintenance ............................................................................................................4-57 General Maintenance ...............................................................................................................4-57 Discharge Check Valve ............................................................................................................4-59 Compressor Receiver Tank Assembly ......................................................................................4-60 Separator Elements..................................................................................................................4-61 Separator Elements – Remove and Replace ...........................................................................4-62 Scavenge Line..........................................................................................................................4-63 Compressor Discharge Temperature Gauge, Switch and Sender ...........................................4-65 Minimum Pressure Valve ..........................................................................................................4-66 Minimum Pressure / Check Valve Maintenance .......................................................................4-66 Thermal Bypass Valve ..............................................................................................................4-67 Thermal Bypass Valve Maintenance ........................................................................................4-68 Compressor Fluid Filter ............................................................................................................4-70 Changing Filter Elements .........................................................................................................4-71 Bearing Oil Filter .......................................................................................................................4-72 Oil stop valve ............................................................................................................................4-73 Compressor Inlet Valve Control System ...................................................................................4-74 Compressor Regulation ............................................................................................................4-77 Relieving Regulators ................................................................................................................4-78 System Blowdown Valve ..........................................................................................................4-80 Running Blowdown Valve .........................................................................................................4-81 Running Blowdown Maintenance .............................................................................................4-82 Coalescing Filter .......................................................................................................................4-83 Troubleshooting ........................................................................................................................4-84 Coolers ..........................................................................................................................................4-86 Compressor Oil Cooler .............................................................................................................4-86 Hydraulic Oil / Radiator Cooler Assembly ................................................................................4-87 Aluminium Tube Air to Oil Cooler ...............................................................................................4-88 Aluminium Tube Air to Oil Cooler – Standard Parts .................................................................4-88 BI620423
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Bucyrus International, Inc.® SKSS-13 Introduction Int-10 March, 11 Version 1 Contents Removal Replacement .............................................................................................................4-89 Internal Cleaning ......................................................................................................................4-91 Radiator Cooler .............................................................................................................................4-93 Typical Radiator Core – Standard Parts ...................................................................................4-93 Cleaning ...................................................................................................................................4-94 Tube Removal ..........................................................................................................................4-95 Seal Installation ........................................................................................................................4-96 Lubricating Seals and Tube Ends.............................................................................................4-96 Tube Installation .......................................................................................................................4-97 Notes ............................................................................................................................................4-100 Section 5 - Dust Control System ..................................................... 5-1 Section 5 Contents .........................................................................................................................5-3 Dust Control System ......................................................................................................................5-5 Dust Control Systems .................................................................................................................5-5 Water Injection ................................................................................................................................5-7 Dust Collector and Water Injection Circuit ..................................................................................5-7 Water Tanks................................................................................................................................5-8 Water Injection Pump .................................................................................................................5-9 Water Injection Relief Valve........................................................................................................5-9 Water Injection Control .............................................................................................................5-10 Water Injection Basic Circuit.....................................................................................................5-12 Water Pump ...................................................................................................................................5-13 Water Injection Pump Assembly ...............................................................................................5-13 Pump Specifications .................................................................................................................5-14 Torque Requirements ...............................................................................................................5-14 Servicing Instructions ...............................................................................................................5-14 Servicing the Plunger Packings................................................................................................5-14 Reassembling Plunger Packings..............................................................................................5-15 Servicing the Pump Valves .......................................................................................................5-15 Reassembling Valve Parts .......................................................................................................5-15 Servicing the Crankshaft ..........................................................................................................5-16 Servicing the Crossheads ........................................................................................................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 Pump Drive Coupling .....................................................................................................5-21 Level and Flow Transducer ......................................................................................................5-21 Notes ..............................................................................................................................................5-22
6
................................... 6-1 Section 6 Contents .........................................................................................................................6-3 BI620423
Section
- Mast / Rotary Drive / Pipe Rack
Bucyrus International, Inc.® March, 11 Version 1 Int-11 SKSS-13 Introduction Contents Mast Weldment................................................................................................................................6-5 Mast Repair ................................................................................................................................6-5 Weld Inspection Schedule .............................................................................................................6-6 Mast Inspection ..........................................................................................................................6-6 Mast Assembly and Installation ....................................................................................................6-7 Mast Assembly 13m ...................................................................................................................6-7 Mast Pivot ...................................................................................................................................6-8 Mast Pivot Bolts..........................................................................................................................6-9 Mast A-frame ............................................................................................................................6-10 Mast A-frame Pivot Shaft Cap Bolts ..........................................................................................6-11 Mast Elevate Cylinders .............................................................................................................6-12 Angle Drilling ............................................................................................................................6-12 Mast / Drill Without Mast ..........................................................................................................6-13 Mast Assembly .........................................................................................................................6-14 Raising the Mast .......................................................................................................................6-14 Feed Cylinders ..............................................................................................................................6-16 Feed Cylinders .........................................................................................................................6-16 Removal ...................................................................................................................................6-18 Feed Cylinder Assembly...........................................................................................................6-19 Repair .......................................................................................................................................6-20 Installation ................................................................................................................................6-20 Hoist / Pulldown Cable Adjustment with Auto Tension.............................................................6-21 Hoist / Pulldown Cable Adjustment with Auto Tension Hydraulic .............................................6-21 Hoist / Pulldown Cables ...........................................................................................................6-22 Adjustment ...............................................................................................................................6-23 Replacement ............................................................................................................................6-25 Wire Rope ................................................................................................................................6-26 Rotary Drive ..................................................................................................................................6-27 Rotary Head Assembly .............................................................................................................6-27 Rotary Head Guide Alignment ..................................................................................................6-28 Rotary Head – Drive System ....................................................................................................6-30 Rotary Drive – Removal from Mast ..........................................................................................6-31 Rotary Drive – Installation ........................................................................................................6-31 Rotary Drive Gearbox – Repair ................................................................................................6-32 Rotary Head Bull Shaft Bearing Nut .........................................................................................6-33 Manufacturers Recommendations – Blast Hole Drilling Consumables ....................................6-34 Air Swivel (Single Seal Style) ...................................................................................................6-35 Deck Wrench .................................................................................................................................6-36 Deck Wrench ............................................................................................................................6-36 H.O.B.O. Wrench ...........................................................................................................................6-37 H.O.B.O Wrench ......................................................................................................................6-37 Breakout System – H.O.B.O ....................................................................................................6-38 Hydraulic Operated Bit Basket – H.O.B.B (Optional) ..............................................................6-38 Pipe Safety Arm........................................................................................................................6-38 Pipe Positioner ..............................................................................................................................6-39 Pipe Positioner .........................................................................................................................6-39 BI620423
Bucyrus International, Inc.® SKSS-13 Introduction Int-12 March, 11 Version 1 Contents Carousel Pipe Rack ......................................................................................................................6-40 Major Components ...................................................................................................................6-40 Rod Handling – Carousal Indexing...........................................................................................6-41 Pipe Rack Assembly.................................................................................................................6-42 General Information..................................................................................................................6-43 Pipe Rack Bearings – Removal................................................................................................6-43 Pipe Rack Components – Inspection .......................................................................................6-45 Pipe Rack – Assembly and Installation ....................................................................................6-46 Pipe Rack Roller – Remove and Replace ................................................................................6-47 Pipe Rack Roller – Disassembly and Assembly .......................................................................6-48 Top Sub Saver ...............................................................................................................................6-50 Replacement Procedure...........................................................................................................6-50 Notes ..............................................................................................................................................6-51 Section 7 - Hydraulic Systems ........................................................ 7-1 Section 7 Contents .........................................................................................................................7-3 Hydraulic Symbols .........................................................................................................................7-7 Hydraulic Symbols ......................................................................................................................7-7 Pressure Setting Sequence ...........................................................................................................7-9 Pressure Setting Sequence........................................................................................................7-9 Hydraulic System .......................................................................................................................7-9 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 AA4VG180 Hydraulic Pump .....................................................................................................7-16 Technical Data ..........................................................................................................................7-18 Port Locations ..........................................................................................................................7-22 Setting Procedure.....................................................................................................................7-23 Charge Pressure, High Pressure, P.O.R and Zero Position Settings .......................................7-24 Set Charge Pressure – 450psi (31bar).....................................................................................7-24 Set Crossover Relief (High Pressure) – 5500psi (380bar) .......................................................7-25 Set Pressure Override (P.O.R) – 5000psi (345bar) ..................................................................7-26 Set Mechanical Zero Position – EP Pump Control ...................................................................7-27 Set Hydraulic Zero Position – EP Pump Control ......................................................................7-28 Removal and Inspection of Charge Pump................................................................................7-29 Removal and Installation of Shaft Seal ....................................................................................7-30 Routine Maintenance ...............................................................................................................7-31 Troubleshooting Procedure ......................................................................................................7-32 Brake Test Procedure ...............................................................................................................7-34 BI620423
Bucyrus International, Inc.® March, 11 Version 1 Int-13 SKSS-13 Introduction Contents Charge Circuit ...............................................................................................................................7-35 Charge Circuit ..........................................................................................................................7-35 Routine Maintenance ...............................................................................................................7-36 Changing Filter Elements .........................................................................................................7-36 Main Pumps Circuit ......................................................................................................................7-37 Main Pumps Circuit ..................................................................................................................7-37 Rotation / Tram Motor Circuit ...................................................................................................7-38 Loop Filters ...................................................................................................................................7-39 Loop Filters ...............................................................................................................................7-39 Routine Maintenance ...............................................................................................................7-39 Loop Filter Cross Section .........................................................................................................7-40 Filter Assembly Loop ................................................................................................................7-41 Changing Filter Elements .........................................................................................................7-42 Rotation Circuit .............................................................................................................................7-43 Rotation Circuit .........................................................................................................................7-43 Rotary Drive Gearbox Motor ........................................................................................................7-44 Rotary Drive Gearbox Motor – Test and Repair .......................................................................7-44 Rotary Gearbox Rotation Motor ...............................................................................................7-45 Shaft Seal Replacement...........................................................................................................7-46 Troubleshooting ........................................................................................................................7-47 Tram Circuit ...................................................................................................................................7-49 Tram Circuit ..............................................................................................................................7-49 Main Closed Loop Circuits...........................................................................................................7-50 Operation ..................................................................................................................................7-50 Feed and Auxiliary Pump Circuit .................................................................................................7-51 Hydraulic Piston Pumps – Removal and Replacement ............................................................7-51 Feed and Auxiliary Functions Pump .........................................................................................7-54 Repair Instructions ...................................................................................................................7-55 Pump Replacement – Start Up.................................................................................................7-56 Auxiliary and Feed Circuits .......................................................................................................7-58 Pilot Control Manifold...................................................................................................................7-59 Hydraulic Valve Stand Assembly ..............................................................................................7-59 Pilot Control Manifold ...............................................................................................................7-60 Pilot Control Manifold Assembly ...............................................................................................7-61 Control Valve Assembly ............................................................................................................7-62 Hydraulic Feed Circuit ..................................................................................................................7-69 Hydraulic Feed Circuit ..............................................................................................................7-69 Feed Valve Assembly ...............................................................................................................7-71 M4-22 Hoist / Pulldown Control Valve ......................................................................................7-73 M4-22 Hoist / Pulldown Control Valve Schematic ....................................................................7-74 Control Valve Assembly ...............................................................................................................7-75 Technical Data ..........................................................................................................................7-75 Jack Control and Mast Elevating Circuit ....................................................................................7-76 Jack Control and Mast Elevating Control Valve .......................................................................7-76 OEM Controllers / EP Levers ...................................................................................................7-77 Counterbalance Valves ................................................................................................................7-78 Counterbalance Valve Adjustment ...........................................................................................7-78 BI620423
Bucyrus International, Inc.® SKSS-13 Introduction Int-14 March, 11 Version 1 Contents Levelling Jack Cylinders ..............................................................................................................7-79 Jack Leg Cylinder .....................................................................................................................7-79 Counterbalance Valve Test Procedure .....................................................................................7-79 Mast Elevating Cylinder ...............................................................................................................7-80 Mast Elevating Cylinder............................................................................................................7-80 Counterbalance Valve Test Procedure .....................................................................................7-81 Auxiliary Pump Circuit .................................................................................................................7-82 Auxiliary Functions Circuit ........................................................................................................7-82 Auxiliary Valves ........................................................................................................................7-83 AWE6 Auxiliary Valves .............................................................................................................7-84 Exploded View ..........................................................................................................................7-86 Hydraulic Operated Breakout Wrench ........................................................................................7-87 H.O.B.O Wrench ......................................................................................................................7-87 H.O.B.O Wrench Circuit ...........................................................................................................7-88 Setting of H.O.B.O Sequence Valves .......................................................................................7-89 H.O.B.O Float Valve .................................................................................................................7-89 Pipe Positioner ..............................................................................................................................7-90 Pipe Positioner .........................................................................................................................7-90 Pipe Safety Arm........................................................................................................................7-91 Hydraulic Gear Pumps .................................................................................................................7-92 Hydraulic Gear Pumps – Removal and Replacement ..............................................................7-92 Hydraulic Gear Pumps – Repairs, Operation, Specifications and Adjustment .........................7-92 Hydraulic Gear Pumps – Shaft Seal Removal and Replacement ............................................7-93 Tool List ....................................................................................................................................7-94 Cooler Fan Circuit .........................................................................................................................7-95 Fan Motor Circuit ......................................................................................................................7-95 Basic Cooler Fan Circuit (Hot and Cold) ..................................................................................7-96 Cooler Fan Motor ..........................................................................................................................7-97 Hydraulic Motor ........................................................................................................................7-97 Cooler Fan Motor Assembly .....................................................................................................7-99 Hydraulic Thermostatic Valve ....................................................................................................7-101 Hydraulic Cooler – Thermal Valve ..........................................................................................7-101 Water Injection ............................................................................................................................7-102 Water Injection Valve ..............................................................................................................7-102 Water Injection Circuit ............................................................................................................7-103 Water Pump Motor ......................................................................................................................7-104 Water Pump Motor Repair Information ...................................................................................7-104 Shaft Seal Repair ...................................................................................................................7-105 Air Conditioner ............................................................................................................................7-108 Air Conditioner Compressor Drive Circuit ..............................................................................7-108 Air Conditioning Drive Motor ..................................................................................................7-109 Hydraulic Cylinder Repair ...........................................................................................................7-112 Hydraulic Cylinders .................................................................................................................7-112 General Information.................................................................................................................7-113 H Head ....................................................................................................................................7-115 N Head ....................................................................................................................................7-116 BI620423
N.B: For further information on specific electronic components, please refer to Vendor Documents in Table of Contents on Service Manual CD.
Bucyrus International, Inc.® March, 11 Version 1 Int-15 SKSS-13 Introduction Contents Z Head .....................................................................................................................................7-117 Z Head (Two Piece).................................................................................................................7-118 K Head ....................................................................................................................................7-119 M Head ...................................................................................................................................7-120 Z Piston ..................................................................................................................................7-121 Z Piston (Threaded) ...............................................................................................................7-122 H and K Piston .......................................................................................................................7-123 M Piston .................................................................................................................................7-124 N Piston ..................................................................................................................................7-127 Hydraulic Systems ......................................................................................................................7-128 Main Hydraulic Schematic ......................................................................................................7-128 Notes ............................................................................................................................................7-129 Section 8 - Electrical components ................................................. 8-1 Section 8 Contents .........................................................................................................................8-3 Electrical Locator ............................................................................................................................8-5 Electrical Component Location...................................................................................................8-5 Jump Starting ..................................................................................................................................8-8 Jump Starting .............................................................................................................................8-8 Batteries ........................................................................................................................................8-10 Batteries ...................................................................................................................................8-10 Welding Precautions .....................................................................................................................8-11 Welding Precautions .................................................................................................................8-11 Electrical Components .................................................................................................................8-12 Electrical Circuits ......................................................................................................................8-12 Transducers..............................................................................................................................8-12 EP Levers .................................................................................................................................8-13 Joystick Adjustments ................................................................................................................8-14 Vigilante Guide ..............................................................................................................................8-16 Important Information ...............................................................................................................8-16 PLC ..........................................................................................................................................8-17 Touchscreen .............................................................................................................................8-20 Laser Depth System .................................................................................................................8-21 Distance Meter .........................................................................................................................8-24 Start-up and Shutdown.............................................................................................................8-24 Hydraulic Function Enable .......................................................................................................8-24 Alarms ......................................................................................................................................8-25 Solenoid Control .......................................................................................................................8-25 Auto Lube .................................................................................................................................8-28 Gauges .....................................................................................................................................8-28 Level Switches .........................................................................................................................8-30 Fan Speed Module ...................................................................................................................8-31 Dust Suppression .....................................................................................................................8-31 Acknowledgements ..................................................................................................................8-32 Disclaimers ...............................................................................................................................8-32 Notes ..............................................................................................................................................8-34
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Bucyrus International, Inc.® SKSS-13 Introduction Int-16 March, 11 Version 1 Contents Section 9 - Lubrication and Preventive Maintenance .................... 9-1 Section 9 Contents .........................................................................................................................9-3 Central Lube System ......................................................................................................................9-5 Auto Lube Basic Operation ........................................................................................................9-5 Central Lube Tank Assembly ......................................................................................................9-6 Auto Lube Grease Pump – Owner / Operator Manual ..............................................................9-7 Auto Lube Tube Pump – Owner / Operator Manual .................................................................9-13 Graco Vent Valve ......................................................................................................................9-18 Central Lube System Circuit.....................................................................................................9-19 Basic Operational Principles of Auto Lube Injectors.................................................................9-20 SL-V and SL-V XL Injectors......................................................................................................9-20 SL-1 and Sl-11 Injectors ...........................................................................................................9-21 SL-32 Injectors .........................................................................................................................9-22 Typical Grease System Circuit .................................................................................................9-23 First 50 Hours Service ..............................................................................................................9-24 Lube Faults / Operation ............................................................................................................9-25 Auto Lube Timer .......................................................................................................................9-26 Lube Pressure Screen..............................................................................................................9-26 Air Service Units ...........................................................................................................................9-27 Air Service Unit System ............................................................................................................9-27 Soft Start Dump Valve ..............................................................................................................9-28 Filter Regulator .........................................................................................................................9-29 Air Line Oiler .............................................................................................................................9-30 Air Service Unit .........................................................................................................................9-31 Pipe Thread Lubricator ................................................................................................................9-32 Air Operator Pipe Thread Pump ...............................................................................................9-32 Filter Locator .................................................................................................................................9-40 Filter Locator Assembly ............................................................................................................9-40 Lubrication and Preventive Maintenance ...................................................................................9-41 General Lubrication ..................................................................................................................9-41 Equipment Lubrication..............................................................................................................9-41 Care of Lubrication Points ........................................................................................................9-41 Safety .......................................................................................................................................9-42 Isolation – Battery Switch .........................................................................................................9-43 Track Gear................................................................................................................................9-44 Engine Maintenance.................................................................................................................9-45 Air Cleaners ..............................................................................................................................9-46 Air Filter Elements ....................................................................................................................9-46 Alternator Maintenance ............................................................................................................9-46 Pump Drive and Drive Shaft Maintenance ...............................................................................9-47 Compressor Maintenance ........................................................................................................9-47 Cooler Packs ............................................................................................................................9-47 A-frame and Pivot Point Maintenance ......................................................................................9-49 Pulldown and Hoist Ropes and Sheaves Maintenance............................................................9-49 Rotary Head Maintenance........................................................................................................9-49 BI620423
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