CAT Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1M68M11 – PDF DOWNLOAD by www.heydownloads.com

Technical Manual

BI620405

BUCYRUS

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Think Terex, Think Integrity SKF-12 Infinity Blasthole Drill Serial No.1M68M11 Service Manual SERVICE MANUAL PART NO. 91-A11-442 June 2010, Version 2 BI620405

BI620405

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: _____________________________________________________________________

SKF Introduction Int-3 Contents Safety Information BI620405

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

Int-4 SKF Introduction Contents Parts Ordering and Product Support BI620405

Parts Ordering and Product Support

SKF Introduction Int-5 Contents Section 1 - Safety..............................................................................1-1 Section 1 Contents .........................................................................................................................1-3 Safety ...............................................................................................................................................1-4 Personal Protective Equipment ..................................................................................................1-4 Noise ..........................................................................................................................................1-4 Electrical Contact .......................................................................................................................1-4 Overhead and Buried Utilities.....................................................................................................1-4 Contact with Electric Wires .........................................................................................................1-5 Contaminated Air ........................................................................................................................1-5 Machine Stability ........................................................................................................................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 Safety Locator ...........................................................................................................................1-11 General 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 .............................................................................................................................2-10 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 ......................................................................................................................2-24 Cab Foot Controls ....................................................................................................................2-24 Thread Grease Switch..............................................................................................................2-24 Pipe Safety Arm Override Switch .............................................................................................2-24 Air Conditioner ..............................................................................................................................2-25 T8 Series Split System Air Conditioning Manual Contents.......................................................2-25 Section 1.0 Technical Data and Control Settings .....................................................................2-26 Section 2.0 Installation and Commissioning.............................................................................2-28 Section 3.0 Routine Maintenance Procedures .........................................................................2-32 Section 4.0 Fault Diagnosis......................................................................................................2-33 Section 5.0 Basic Spare Parts Listing ......................................................................................2-42 Section 6.0 Reference Drawings ..............................................................................................2-44 Zexel DK-32 Compressor .........................................................................................................2-48 Performance Curve ..................................................................................................................2-49 Notes ..............................................................................................................................................2-50 BI620405

Int-6 SKF Introduction Contents Section 3 - Main Frame / Crawlers ..................................................3-1 Section 3 Contents .........................................................................................................................3-3 Main Frame Repair – General ........................................................................................................3-5 Main Frame Repair .....................................................................................................................3-5 Levelling Jacks ...............................................................................................................................3-6 Levelling Jacks ...........................................................................................................................3-6 Levelling Jack Cylinders .............................................................................................................3-7 Mast Elevating Cylinders ...............................................................................................................3-8 Crawler Assembly ...........................................................................................................................3-9 Crawler Component Repair ........................................................................................................3-9 Metric Bolt Torque Specifications ...............................................................................................3-10 Track Maintenance.........................................................................................................................3-11 Before Operating the Machine ..................................................................................................3-11 General Maintenance ................................................................................................................3-11 Track Tension Adjustment ...........................................................................................................3-12 Idler Unit ........................................................................................................................................3-14 General Description..................................................................................................................3-14 Removal and Disassembly .......................................................................................................3-16 Assembly and Installation.........................................................................................................3-18 Track Tension Unit ........................................................................................................................3-20 Installation ................................................................................................................................3-21 Track Rollers .................................................................................................................................3-22 General Description..................................................................................................................3-22 Removal and Disassembly .......................................................................................................3-24 Track Roller – Assembly ...........................................................................................................3-25 Track Roller – Test and Install ..................................................................................................3-26 Support Rollers .............................................................................................................................3-27 General Description..................................................................................................................3-27 Support Roller Assembly ..........................................................................................................3-28 Removal and Disassembly .......................................................................................................3-29 Track Chain – Separate ................................................................................................................3-32 Track Chain Separate...............................................................................................................3-32 Track Chain – Repair ....................................................................................................................3-33 Track Link – Description ...........................................................................................................3-33 Track Link – Repair and Replace .............................................................................................3-33 Track Shoes Installation...............................................................................................................3-35 Track Link Position ...................................................................................................................3-35 Track Shoe – Mounting to Tracks Chain ..................................................................................3-35 Track Shoe Bolt Torque (Direct Torque Method) .......................................................................3-36 Track Shoe Bolt Torque (Torque Turn Method) .........................................................................3-37 Track Chain and Shoe Installation ..............................................................................................3-38 Track Chain with Shoes............................................................................................................3-38 Track Chain and Shoe – Assembly and Installation .................................................................3-38 Track and Support Rollers ...........................................................................................................3-40 General Description..................................................................................................................3-40 Track Roller – Removal and Disassembly................................................................................3-41 BI620405

SKF Introduction Int-7 Contents Support Roller – Assembly and Disassembly...........................................................................3-41 Track and Support Roller – Assembly ......................................................................................3-42 Track and Support Roller – Test and Install..............................................................................3-43 Final Drive .....................................................................................................................................3-46 Final Drive – General Description ............................................................................................3-46 Final Drive Unit Removal .............................................................................................................3-47 Removal from Track Frame ......................................................................................................3-47 Final Drive Unit Installation .........................................................................................................3-48 Installation into Track Frame ....................................................................................................3-48 Final Drive Maintenance ...............................................................................................................3-49 Oil Check / Change ..................................................................................................................3-49 Final Drive Oil ................................................................................................................................3-50 Specifications ...........................................................................................................................3-50 Recommended Oils ..................................................................................................................3-50 Final Drive Assembly ....................................................................................................................3-52 Parking Brake – Description .....................................................................................................3-54 Parking Brake – Removal and Installations..............................................................................3-55 Towing Procedures – Gear Drive Disconnect...........................................................................3-55 Repair Manual ..........................................................................................................................3-56 A – General Instructions ...........................................................................................................3-57 B – Safety Instructions .............................................................................................................3-62 C – General Specifications .......................................................................................................3-66 D – Disassembly and Assembly Operation ..............................................................................3-74 E – Troubleshooting ...............................................................................................................3-108 F – Special Tools ....................................................................................................................3-109 Auxiliary Crane ............................................................................................................................3-110 Hydraulic Crane (Auxiliary Crane) ...........................................................................................3-110 Maintenance ............................................................................................................................3-111 Checking of Worm Gear ..........................................................................................................3-111 Notes .............................................................................................................................................3-112 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 BI620405

Int-8 SKF Introduction Contents 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 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 Drive Assembly – Removal and Replacement ...............................................................4-27 Pump Drive Gearbox ....................................................................................................................4-28 Pump Drive Gearbox – Repair .................................................................................................4-28 Hydraulic Pumps ..........................................................................................................................4-30 Hydraulic Pump Identification ...................................................................................................4-30 Hydraulic Pump – Removal and Replacement.........................................................................4-31 Compressor Service Procedures ................................................................................................4-32 Compressor Drive Coupling .....................................................................................................4-32 Compressor Drive Coupling – Removal and Replacement ......................................................4-32 Taper-Loc Bushing Installation – Model ACT5. SN. F2. V1. 3535 ............................................4-34 Before Installation and Start-up of New or Rebuilt Compressor...............................................4-35 Compressor Unit – Installation .................................................................................................4-35 Compressor Shaft Seal ................................................................................................................4-36 High Pressure Compressosr .......................................................................................................4-39 Safety .......................................................................................................................................4-39 Description ...............................................................................................................................4-42 Compressed Air Functions .......................................................................................................4-42 Compressor Oil Circuit ................................................................................................................4-46 Compressor Condensation Table ...............................................................................................4-49 Compressor Air Circuit ................................................................................................................4-50 Compressor Air Circuits – 1475cfm @ 500psi..........................................................................4-50 Compressor Air Circuit Diagram Legend ..................................................................................4-51 Compressor Functional Description ...........................................................................................4-65 Compressor Operation .................................................................................................................4-67 Operation ..................................................................................................................................4-67 Compressor Maintenance ............................................................................................................4-70 General Maintenance ...............................................................................................................4-70 Interstage Tube ........................................................................................................................4-72 Discharge Check Valve ............................................................................................................4-73 Separator / Receiver Tank .......................................................................................................4-74 BI620405

SKF Introduction Int-9 Contents Scavenge Line..........................................................................................................................4-76 Compressor Discharge Temperature Gauge, Switch and Sender ...........................................4-77 Minimum Pressure / Check Valve ............................................................................................4-78 Minimum Pressure / Check Valve Maintenance .......................................................................4-78 Thermal Bypass Valve ..............................................................................................................4-79 Thermal Bypass Valve Maintenance ........................................................................................4-80 Compressor Fluid Filter ............................................................................................................4-81 Changing Filter Elements .........................................................................................................4-81 Fluid Stop Valve .......................................................................................................................4-83 Inlet Valve .................................................................................................................................4-85 Relieving Regulators ................................................................................................................4-87 Reducing Regulators ................................................................................................................4-90 Reducing Regulators Maintenance ..........................................................................................4-90 System Blowdown Valve ..........................................................................................................4-92 Running Blowdown Valve .........................................................................................................4-93 Running Blowdown Maintenance .............................................................................................4-94 Moisture Separator Maintenance .............................................................................................4-95 Auxiliary Regulators .................................................................................................................4-96 Auxiliary Regulator Maintenance..............................................................................................4-98 Troubleshooting ......................................................................................................................4-100 Compressor Oil Cooler Assembly .............................................................................................4-103 Compressor Oil Cooler ...........................................................................................................4-103 Hydraulic Oil / Radiator Cooler Assembly ................................................................................4-104 Hydraulic Oil / Radiator Cooler Assembly ..............................................................................4-104 Coolers Maintenance ..................................................................................................................4-105 Compressor Oil / Hydraulic Oil Cooler Service Manual ..........................................................4-106 Radiator Cooler Service Manual .................................................................................................4-111 Notes .............................................................................................................................................4-117 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 Injection Relief Valve........................................................................................................5-7 Water Injection Control ...............................................................................................................5-8 Water Injection Basic Circuit.....................................................................................................5-10 Water Pump ....................................................................................................................................5-11 Pump Specifications ..................................................................................................................5-11 Servicing Instructions ................................................................................................................5-11 Parts List ..................................................................................................................................5-12 Replacing Piston Cup Seals .....................................................................................................5-13 Replacing Suction and Discharge Valves .................................................................................5-14 Replacing Power End Bearings................................................................................................5-15 Servicing the Wrist Pin Bearings ..............................................................................................5-16 BI620405

Int-10 SKF Introduction Contents Fastener Torque Requirements ................................................................................................5-16 Recommended Lubricants .......................................................................................................5-17 Water Pump Motor Repair ........................................................................................................5-17 Water Injection Hydraulic Control Valve Repair........................................................................5-17 Water Pump Drive Coupling .....................................................................................................5-17 Level and Flow Transducer ......................................................................................................5-17 Foam Injection System .................................................................................................................5-18 Foam Injection System Manual ................................................................................................5-18 Routine Maintenance ...............................................................................................................5-21 Maintenance Schedule .............................................................................................................5-25 Fault Finding .............................................................................................................................5-28 Notes ..............................................................................................................................................5-32 Section 6 - Mast / Rotary Drive / Pipe Rack....................................6-1 Section 6 Contents .........................................................................................................................6-3 Mast Weldment................................................................................................................................6-5 Mast Repair ................................................................................................................................6-5 Mast Assembly ................................................................................................................................6-6 Mast Assembly ...........................................................................................................................6-6 Mast Pivot Caps .........................................................................................................................6-7 Mast Elevate Cylinders ...............................................................................................................6-7 Angle Drilling ..............................................................................................................................6-8 Feed Cylinders ................................................................................................................................6-9 SKF Feed System ......................................................................................................................6-9 Feed Cylinder – Removal .........................................................................................................6-10 Feed Cylinder Assembly............................................................................................................6-11 Feed Cylinder Repair ...............................................................................................................6-12 Feed Cylinder Installation .........................................................................................................6-12 Hoist / Pulldown Cable Assembly ...............................................................................................6-13 Hoist / Pulldown Cable Adjustment ............................................................................................6-14 Auto Tensioning – Operating Principle .....................................................................................6-14 Auto Tensioning – Cable Removal, Adjustment and Installation ..............................................6-14 Rope Tensioning Circuit ...........................................................................................................6-16 Wire Rope ................................................................................................................................6-18 Sheave Rollers .........................................................................................................................6-18 Rotary Head Guide Alignment .....................................................................................................6-19 Alignment Procedure ................................................................................................................6-19 Rotary Drive Assembly .................................................................................................................6-20 Rotary Drive – Removal from Mast ..........................................................................................6-21 Rotary Drive – Installation ........................................................................................................6-21 Rotary Drive Gearbox ...................................................................................................................6-22 Air Swivel (Single Seal Style) ...................................................................................................6-24 Air Swivel Service .....................................................................................................................6-24 Rotary Drive Motor – Repair .....................................................................................................6-25 Rotary Drive Rebuild Manual ...................................................................................................6-26 BI620405

SKF Introduction Int-11 Contents Winch Assembly ...........................................................................................................................6-66 Precautions On The Use Of Winches ......................................................................................6-66 Wire Rope ................................................................................................................................6-66 Wedge Socket ..........................................................................................................................6-68 Grooved Drums ........................................................................................................................6-69 Plain (Smooth) Drums ..............................................................................................................6-69 Drums – Multiple Layers ...........................................................................................................6-69 Winch Assembly Service ..........................................................................................................6-70 BG8A and BG8B Hydraulic Winch Service Manual..................................................................6-71 H.O.B.O. Wrench .........................................................................................................................6-102 Tong Dies ...............................................................................................................................6-103 Deck Wrench ...............................................................................................................................6-104 Pipe Positioner ............................................................................................................................6-105 Carousel Pipe Rack ....................................................................................................................6-106 If Pipe Rack Does Not Rotate ................................................................................................6-106 Chain Drive – Adjust / Replace...............................................................................................6-106 Pipe Rack Bearings – Replace...............................................................................................6-107 Carousel Top Tube Bearing – Replace ...................................................................................6-108 Carousel Lower Bearing – Replace.........................................................................................6-110 Carousel Pivot Support Upper Bearing – Replace ..................................................................6-112 Carousel Pivot Support Lower Bearing – Replace ..................................................................6-114 Mid Point Carousel Pivot Support ...........................................................................................6-115 Carousel Rotate Motor ............................................................................................................6-115 Notes .............................................................................................................................................6-116 Section 7 - Hydraulic Systems ........................................................7-1 Section 7 Contents .........................................................................................................................7-3 Hydraulic Symbols .........................................................................................................................7-5 Hydraulic Tank ................................................................................................................................7-7 Pressure Setting Sequence ...........................................................................................................7-9 Pressure Setting Sequence........................................................................................................7-9 Hydraulic System .......................................................................................................................7-9 Main Return and Case Drain Filter ..............................................................................................7-10 Routine Maintenance ................................................................................................................7-11 Changing Filter Elements ..........................................................................................................7-11 Main Hydraulic Pumps .................................................................................................................7-12 Hydraulic Pump Identification - SKF12.....................................................................................7-12 Hydraulic Piston Pumps Removal and Replacement ...............................................................7-13 Hydraulic Piston Pumps – Operation, Specifications, Adjustment and Repair .........................7-13 Right Track / Pulldown, Left Track / Rotation Pumps ...............................................................7-14 Main Pumps .............................................................................................................................7-14 AA4VG125 Hydraulic Pump EP2 Control.................................................................................7-14 AA4VG EP Controller ...............................................................................................................7-16 Technical Data ..........................................................................................................................7-17 EP (24V DC) Control ................................................................................................................7-19 Schematic Drawing – Standard Model .....................................................................................7-19 BI620405

Int-12 SKF Introduction Contents Port Locations ..........................................................................................................................7-22 Connections .............................................................................................................................7-22 Main Pump Adjustments...........................................................................................................7-23 Change Pressure, High Pressure, P.O.R. and Zero Positions Setting .....................................7-24 Set Charge Pressure – 450psi (31bar).....................................................................................7-25 Set Pressure Override – 5500psi (380bar)...............................................................................7-25 Set Pressure Override (P.O.R.) – 5000psi (345bar) .................................................................7-26 Mechanical Zero Position .........................................................................................................7-27 Hydraulic Centreing ..................................................................................................................7-28 Removable and Inspection of Charge Pump............................................................................7-29 Removal and Installation of Shaft Steel ...................................................................................7-30 Routine Maintenance ...............................................................................................................7-31 Hydraulic Piston Pumps – Maintenance .....................................................................................7-34 Hydraulic Piston Pumps – Troubleshooting ..............................................................................7-36 Charge Circuit ...............................................................................................................................7-40 Double Gear Pump – Right Charge and Water Injection..........................................................7-40 Routine Maintenance ...............................................................................................................7-43 Changing Filter Elements .........................................................................................................7-43 Loop Filters ...................................................................................................................................7-44 Loop Filters ...............................................................................................................................7-44 Routine Maintenance ...............................................................................................................7-47 Changing Filter Elements .........................................................................................................7-47 Diverter Valve ................................................................................................................................7-48 Operation ..................................................................................................................................7-48 Diverter Valve ...........................................................................................................................7-48 Tram Circuit ...................................................................................................................................7-50 Hoist / Pulldown Circuit................................................................................................................7-52 Basic Pulldown Circuit ..............................................................................................................7-52 Hoist / Pulldown Circuit ............................................................................................................7-53 Rope Tensioning Circuit ..............................................................................................................7-54 Auto Tensioning – Operating Principle .....................................................................................7-54 Rotation Circuit .............................................................................................................................7-56 Rotation Circuit .........................................................................................................................7-56 Rotary Drive Gearbox Motor ........................................................................................................7-58 Rotation Motor ..........................................................................................................................7-62 Fan and Auxiliary Pump Circuit ...................................................................................................7-72 Fan and Auxiliary Functions Pump ...........................................................................................7-74 Hydraulic Pumps ..........................................................................................................................7-75 Hydraulic Piston Pumps – Removal and Replacement ............................................................7-75 Model A11VLO Hydraulic Piston Pumps – Repair ....................................................................7-75 Repair Instructions ...................................................................................................................7-76 New or Rebuilt Hydraulic Pump – Start-up ................................................................................7-77 Start-up Procedure ...................................................................................................................7-77 Auxiliary Functions / Fan Circuit .................................................................................................7-79 Operation ..................................................................................................................................7-80 Auxiliary Priority Function .........................................................................................................7-85 BI620405

SKF Introduction Int-13 Contents Cooler Fan Circuit .........................................................................................................................7-86 Cooler Fan Motor ..........................................................................................................................7-88 Hydraulic Motor F12 Series ......................................................................................................7-91 Jack and Mast Elevate Circuit .....................................................................................................7-92 4 Bank Valve ............................................................................................................................7-92 Counterbalance Valve Adjustment ..............................................................................................7-94 Counterbalance Valve Adjustments ..........................................................................................7-94 Mast Elevating Cylinders .............................................................................................................7-95 Mast Elevating Cylinders Counterbalance Valves ....................................................................7-95 Levelling Jack Cylinders ..............................................................................................................7-96 Jack Counterbalance Valves ....................................................................................................7-96 Auxiliary Functions / 6 Bank Valve .............................................................................................7-97 Auxiliary Functions / 9 Bank Valve .............................................................................................7-99 Hydraulic Operated Breakout Wrench (HOBO) ........................................................................7-100 Setting of Sequence Valves ...................................................................................................7-100 Mast Raise / Jacks Valve and Water Foam Valve ..................................................................7-101 Carousel Rotate Motor ...............................................................................................................7-106 Pilot Control Manifold..................................................................................................................7-113 Electro Proportional Valves ....................................................................................................7-123 Proportional Valve Set-up .......................................................................................................7-124 OEM Electro Proportional Mast Raise / Jacks Valve ..............................................................7-124 Proportional Pulldown ............................................................................................................7-125 OEM Controllers / EP levers ..................................................................................................7-126 Auto Pulldown Card................................................................................................................7-127 Reduced Pulldown Potentiometer 'Pot' ..................................................................................7-128 Hydraulic Gear Pumps ...............................................................................................................7-129 Hydraulic Gear Pumps – Removal and Replacement ............................................................7-129 Hydraulic Gear Pump – Repair ..............................................................................................7-129 Hydraulic Gear Pumps – Shaft Seal Removal and Replacement ..........................................7-130 Dust Collector / Water Injection Circuit ....................................................................................7-132 Water Injection / Foam Injection Valve Circuit ........................................................................7-133 Air Conditioner Compressor Drive Circuit ...............................................................................7-134 Hydraulic Cylinder Repair ..........................................................................................................7-136 General Information................................................................................................................7-137 H Head ...................................................................................................................................7-139 N Head ...................................................................................................................................7-140 Z Head ....................................................................................................................................7-141 K Head ...................................................................................................................................7-143 M Head ...................................................................................................................................7-144 Z Piston ..................................................................................................................................7-145 H and K Piston .......................................................................................................................7-146 M Piston .................................................................................................................................7-147 N Piston ..................................................................................................................................7-150 Notes ............................................................................................................................................7-151 BI620405

Int-14 SKF Introduction Contents Section 8 - Electrical Components .................................................8-1 Section 8 Contents .........................................................................................................................8-3 Electrical Locator ............................................................................................................................8-5 Jump Starting ..................................................................................................................................8-7 Batteries ..........................................................................................................................................8-9 Welding Precautions ....................................................................................................................8-10 Vigilante Guide ...............................................................................................................................8-11 Important Information ................................................................................................................8-11 PLC ..........................................................................................................................................8-12 Touchscreen .............................................................................................................................8-15 Laser Depth System .................................................................................................................8-16 Distance Meter .........................................................................................................................8-19 Start Up and Shut Down...........................................................................................................8-19 Hydraulic Function Enable .......................................................................................................8-19 Alarms ......................................................................................................................................8-20 Solenoid Control .......................................................................................................................8-21 Auto Lube .................................................................................................................................8-24 Hammer Oiler System ..............................................................................................................8-24 Gauges .....................................................................................................................................8-25 Head Speed .............................................................................................................................8-27 Level Switches .........................................................................................................................8-27 Dust Suppression .....................................................................................................................8-28 N.B: For further information on specific electronic components, please refer to Electronic Components Section on Service Manual CD. Acknowledgements ..................................................................................................................8-29 Disclaimers ...............................................................................................................................8-29 Notes ..............................................................................................................................................8-30 Section 9 - Lubrication and Preventive Maintenance ...................9-1 Section 9 Contents .........................................................................................................................9-3 Central Lube System ......................................................................................................................9-5 Hydraulic Control Schematic ......................................................................................................9-6 Auto Lube ...................................................................................................................................9-6 Central Lube System Circuit.......................................................................................................9-8 Central Lube Pump Module......................................................................................................9-10 Central Lube Pump ..................................................................................................................9-23 SL-1 Injectors ...........................................................................................................................9-47 SL-1 Injectors Assembly ...........................................................................................................9-47 SL-1 Injectors Specifications ....................................................................................................9-47 Hammer Oiler Tank Assembly .....................................................................................................9-49 Hammer Oiler Tank Assembly ..................................................................................................9-49 Hammer Oil Circuit .......................................................................................................................9-50 Hammer Oil System ......................................................................................................................9-51 Air Service Unit Components ...................................................................................................9-51 Filter Regulator .........................................................................................................................9-52 Air Line Oiler .............................................................................................................................9-53 Fire Ball 425 Pump – Instructions ............................................................................................9-54 BI620405

SKF Introduction Int-15 Contents Pipe Thread Lubricator ................................................................................................................9-71 Air Service Unit .........................................................................................................................9-71 Filter Regulator .........................................................................................................................9-72 Air Line Lubricator ....................................................................................................................9-73 Pipe Thread Pump ...................................................................................................................9-74 Filter Locator .................................................................................................................................9-82 Filter Location Assembly ..........................................................................................................9-83 Lubrication General ......................................................................................................................9-84 Equipment Lubrication..............................................................................................................9-84 Care of Lubrication Points ........................................................................................................9-84 Lubrication and Preventive Maintenance ...................................................................................9-85 Safety .......................................................................................................................................9-85 Isolation – Battery Switch .........................................................................................................9-86 Track – Check and Lubrication .................................................................................................9-87 Engine Maintenance.................................................................................................................9-88 Air Cleaners ..............................................................................................................................9-89 Air Filter Elements ....................................................................................................................9-89 Alternator Maintenance ............................................................................................................9-89 Compressor – Checks and Servicing .......................................................................................9-90 Air Conditioner – Checks and Servicing ...................................................................................9-91 Drive Shaft – Checks and Maintenance ...................................................................................9-91 Cooler – Checks and Servicing ................................................................................................9-92 Hydraulic – Checks and Servicing............................................................................................9-93 A-frame and Mast Pivot Point – Checks and Maintenance ......................................................9-94 Rotary Head – Checks and Service Points ..............................................................................9-95 Pulldown / Hoist Sheaves and Ropes – Checks and Servicing ...............................................9-96 Cabin – Checks and Service Points .........................................................................................9-97 Fire Suppression (Optional) – Checks and Servicing...............................................................9-97 Battery – Checks and Servicing ...............................................................................................9-98 Bean Pump – Checks and Maintenance ..................................................................................9-98 Lubrication System – Checks and Servicing ............................................................................9-99 250hr Lubrication and Maintenance .........................................................................................9-100 500hr Lubrication and Maintenance ..........................................................................................9-115 1000hr Lubrication and Maintenance .......................................................................................9-131 2000hr Lubrication and Maintenance .......................................................................................9-147 Notes ............................................................................................................................................9-165 BI620405

General Locator

Int-16 SKF Introduction

Foam Tank 1. Engine Oil Reserve Tank 2. Engine Radiator 3. Compressor Air Filter 4. Hammer oil Tank 5. F.S. Tanks 6. Air Receiver Tank 7. Central Lube Tank 8. Engine Air Filters 9. Main Electrical Tank 10.

13.

14.

16.

17.

18.

19. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 BI620405

Hydraulic Tank

11.

Battery Box

12. Transducer

Box Air Conditioner Unit Cotton Reel

15. Hiab

Crane Swinging Gate Kidney Loop Tank

Thread Greaser

ENGINE RADIATOR

COMPRESSOR AIR FILTER

MAST REST

MUFFLER

WINCH

HAMMER OIL TANK

WATER TANK WATER PUMP

MAST ELEVATING CYLINDERS

EMERGENCY STOP

FOAM TANK F.S. ACTUATOR

ENGINE OIL RESERVE TANK CRAWLER

SKF Introduction Int-17 General

Locator

DRILL PIPE SAFETY LINE PIPE RACK MAST CLEARANCE LIGHT

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General Locator

HOIST ROPE

PULLDOWN ROPE

TRAVELLING SHEAVES

HOIST/PULLDOWN CYLINDER

FLASHING LIGHT

WINCH

MAST ACCESS LADDER

MUFFLER

CENTRAL LUBE TANK EMERGENCY STOPS

PRESSURE CLEANER

EMERGENCY STOP

F.S. ACTUATOR

Int-18 SKF Introduction

HAMMER OIL TANK

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Section 1 Safety

CAUTION: DO NOT weld on any part of the machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. On machines equipped with electronic engine, disconnect the connections to the Electronic Control Module (ECM) on the engine before welding (see Section 8).

Safety SKF Safety 1-1

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SKF Safety 1-3 Section 1 - Safety..............................................................................1-1 Section 1 Contents .........................................................................................................................1-3 Safety ...............................................................................................................................................1-4 Personal Protective Equipment ..................................................................................................1-4 Noise ..........................................................................................................................................1-4 Electrical Contact .......................................................................................................................1-4 Overhead and Buried Utilities.....................................................................................................1-4 Contact with Electric Wires .........................................................................................................1-5 Contaminated Air ........................................................................................................................1-5 Machine Stability ........................................................................................................................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 Safety Locator ...........................................................................................................................1-11 General Locator........................................................................................................................1-12 Notes ..............................................................................................................................................1-14 Section 1 Contents BI620405

The Rotary Drill is a heavy moving machine with a mast which raises vertically for drilling. Like all moving objects and reach extending devices, there are potential hazards associated with its use. These hazards will be minimised if the machine is properly inspected and maintained. The maintainers must read this manual and have been trained to use the machine in an appropriate and safe manner. Should any questions arise concerning the maintenance or operation of the machine contact Reedrill in your state or territory.

There are many personal hazards and dangers associated with working on and around a drill rig. If the safety instructions outlined in this section are adhered to, risk of injury or harm to yourself and others will be significantly reduced. In this section and those that follow, the word:

DANGER means that severe injury or death will result from failure to follow instruction.

• WARNING means that severe injury or death can result from failure to follow instruction.

• CAUTION means that minor injury or property damage can result from failure to follow instruction.

•

• NOTE means that special attention should be given to the instruction.

Personal Protective Equipment

Ensure that the minimum PPE is worn at all times when operating or maintaining the machine. Specific PPE may be required when undertaking some tasks or repairs. For example working at height, welding or grinding repairs.

Noise

The Rotary Drill generates high noise while it is in operation therefore, hearing protection is mandatory whenever working in the vicinity of the drill.

Electrical Contact

The Mines Regulation 5.28 states that unless minimum clearances under and in the vicinity of overhead power lines in accordance with AS 3007.5 can be assured, no drilling activity can take place within 10 metres any electrical power-line.

Overhead and Buried Utilities

• and drilling assignment sheets.

Should be located, noted and emphasised on all drilling location plans

• project, consider all wires to be live and dangerous.

Whenever overhead power lines exist on or near a drilling site or

• power lines to gain entrance.

Watch for sagging power lines before entering a site. Do not lift

Before raising a drill rig mast on a site in the vicinity of power lines,

• walk completely around the rig. Determine what the minimum distance from any point on the drill rig to the nearest power line will be when the mast is raised or being raised.

• line or underground utility without a permit indicating 'danger zones' and minimum clearances.

Do not raise the mast or operate the drill rig within a minimum of 10 metres of any electrical power

1-4 SKF Safety Safety

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DANGER: If contact with the machine and power lines should occur it will cause severe injury or death

Contact With Electric Wires

You should observe the following points if the drill comes into contact with live electrical cables:

Do not allow any other personnel to touch any part of the • machine whilst standing on the ground until the power has been isolated

Do not attempt to leave the machine • Follow site emergency procedures •

DANGER: Wait until the power has been switched off before attempting to leave or move the machine

Under most circumstances, you should remain seated or in the position you were in when contact was made. If, however, circumstances (such as fire) make it necessary to leave the machine, then you should JUMP clear and as far as possible from the drill. The critical factor in leaving the machine is the danger of your body completing the electrical circuit, from the power line and the machine, to the ground.

Contaminated Air

Diesel fumes are toxic. Exhaust gasses contain carbon monoxide, a deadly poison, which is colourless and odourless. Therefore, do not run the machine in an area without good ventilation. Compressed air is toxic and should never be directly inhaled.

DANGER: Contaminated air will cause severe injury or death

SKF Safety 1-5 Safety

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Safety

Machine Stability

• potentially collapse or subside.

•

The machine should never be propelled over areas that could

Visual inspections of the path to be taken must be made

All precautions relating to underground workings must be adhered to

• holding water

•

Never tram through areas of soft unconsolidated materials

If propelling on inclines is required, never travel across grades

• undulating ground

•

Do not tram the machine with the tower raised over rough or

Always ensure jacks are lowered onto solid stable ground

WARNING: Unit overturn can cause serious injury or death

AND SHOULD NOT BE USED AS A RECOMMENDATION FOR SAFE OPERATION.

TRAM STABILITY IS VERY DEPENDENT ON OPERATOR EXPERIENCE, KNOWLEDGE AND JUDGEMENT, ACCORDINGLY, REEDRILL IS RELUCTANT TO COMMIT TO ACTUAL VALUES.

1-6 SKF Safety

TOTAL WEIGHT, FULLY LADEN 98 TONNES 9.90 = 17.5% 15.80 = 28% 180 = 32.5% 25.20 = 47% 7.70 = 14% 13.50 = 24%

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THE NUMBERS CONTAINED ON THIS DRAWING ARE GIVEN ONLY AS A GUIDELINE

Moving and Rotating Parts

• clear of the area.

The machine should not be operated unless all people are well

• should be activated with another person on the deck or in the vicinity of the machine unless clear communication methods have been established.

•

The drill is designed for single person operation and no control

Do not lubricate or service while machine is running.

WARNING: Moving parts can cause serious injury or death

High Pressure Air or Fluid

The maintainers must never underestimate the forces exerted by high-pressure air and fluids. Pressure on hydraulic and pneumatic systems must be relieved prior to loosening hoses or connections.

WARNING: High-pressure air or fluid can cause severe injury or death

Before Operation

Study and fully understand this manual.

• Wear all mandatory (i.e. safety helmet, eye protection, hearing protection) and other necessary

• Personal Protective Equipment when operating or working on or in the vicinity of the machine.

• good condition.

Be sure all safety guards, hand rails and access steps or ladders are securely in place and in

Always maintain three-point contact when mounting and dismounting the machine and never • attempt to carry tools or equipment when getting on the machine. Place equipment on the drill prior to climbing the access ladders.

Be sure all connections in compressed air lines are coupled and secured, and that hose socks • are in place and secured to prevent accidental disconnection.

Be sure that all personnel are clear of the machine and work area before starting the engine or • operating the machine.

SKF Safety 1-7 Safety

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Be sure that prior to starting the machine, all controls are in • neutral or off positions and that controls are in the position that will generate the least load upon the engine on start-up. Especially ensure the auto pulldown is off and rotation lever is in neutral.

Be sure that the drill area is clear of all obstructions before • operating the machine. Ensure that the safety chain is attached when using • a towbar.

Do not operate the machine with: a hydraulic leak, broken • or damaged electrical wiring or damaged hydraulic hoses or fittings.

Do not operate the machine without familiarising yourself • with the location of all hand held fire extinguishers.

Be sure the fire suppression system has not been activated, • is still pressurised, and that lines and nozzles are in the correct place and not damaged.

Do not operate the machine without familiarising • yourself with the location of on-board fire suppression activation points.

Do not operate the machine without first checking that all • emergency stops are operational and familiarising yourself as to their location.

During Operation

Do not use the machine for anything other than its designed • purpose for blasthole drilling.

Do not wear jewellery or loose fitting clothing when • working on the machine. Keep clothing and hands clear of moving parts.

Do not move the machine if the drill is in a potentially • unstable position.

Always be aware of the drill rigs automated functions and • make sure people are clear of all components. The Rotary Drill has an automated function of the dust curtain raise/ lower cylinders when the machine is switched from 'Drill' to 'Propel' mode.

Do not propel the machine with the mast raised over • undulating ground or across grades or over any distance other than short distances on a drill pattern.

1-8 SKF Safety Safety

Auto Pulldown Off Emergency Stop

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Dust Curtain Raised

•

Always check blind spots prior to propelling.

•

Do not carry out any drilling activity on a bench until it has been examined for misfires.

• explosives. Site rules may stipulate further distances.

Do not drill a hole so that any portion of the hole is closer than 6 metres to a hole containing

• carbon monoxide, a deadly poison which is colourless and odourless.

Ensure adequate ventilation when running the engine in an enclosed area. Exhaust gases contain

Ensure the drill pipes are secure in the carousel before raising or lowering the mast.

• Before lowering the mast, do make sure the carousel is rotated, locked in the non-pipe-loading

• centre position to ensure pipes are secured so they cannot possibly slide back and fall out of the carousel. Then swing the carousel in towards the centre of the mast.

•

Do make sure dust is suppressed whilst drilling using either the dust collector or water injection.

• ensure secure footing.

Do not climb the ladder to the operator cabin roof whilst the machine is running and always

Do not under any circumstance climb the ladder giving access to the mast without wearing the

• appropriate safety harness. Only ever perform service work on the mast wearing approved fall arrest equipment.

• Do not propel the machine with the mast up.

Do not travel on steep inclines, soft or unstable ground or close to unsupported excavations.

•

SKF Safety 1-9 Safety

Shaded area defines the operators general line of sight when in the seated position

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Defines the area captured by closed circuit cameras (if fitted)

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