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.® July, 10 Version 1 Int-3 SKSS 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 Level 8, 369 Ann Street 139 Racecourse Road 10-12 Corporate Drive Brisbane 4000 Rutherford NSW 2320 Mackay QLD 4740 Ph: (07) 3009 3600 Ph: (02) 4932 0000 Ph: (07) 4952 0600 Fax: (07) 3009 3699 Fax: (02) 4932 0733 Fax: (07) 4952 0666 © Bucyrus International, Inc 2007
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 Introduction Int-4 July, 10 Version 1
Safety Information
Bucyrus International, Inc.® July, 10 Version 1 Int-5 SKSS Introduction Contents Section 1 – Safety ............................................................................. 1-1 Section 1 Contents .........................................................................................................................1-3 Safety ...............................................................................................................................................1-5 Personal Protective Equipment ..................................................................................................1-5 Noise ..........................................................................................................................................1-5 Electrical Contact .......................................................................................................................1-5 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 Safety Locator ...........................................................................................................................1-11 Notes ..............................................................................................................................................1-13 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 Control Panel and Instrument Panels ..........................................................................................2-11 Control Panels ...........................................................................................................................2-11 Right Hand Control Panel..........................................................................................................2-11 Systems Pressure Gauge Panel ..............................................................................................2-13 Switch Panel .............................................................................................................................2-15 Switches / Diagnostic / Control Panel Circuit ...........................................................................2-18 Machine Stability ..........................................................................................................................2-20 Tramming Procedure for SK Series Drills.................................................................................2-20 Track Adjustments ....................................................................................................................2-20 New Machine Procedure ..........................................................................................................2-21 General Maintenance Checks While Tramming .......................................................................2-21 Roller Locations........................................................................................................................2-22 Temperature and Condition Record Chart for Walking .............................................................2-23 Propelling the Machine .............................................................................................................2-24 Stability Limits ..........................................................................................................................2-26 SKS Transient Stability Limits ..................................................................................................2-27 Cab Heater .....................................................................................................................................2-28 Cab Heater Fault Isolation........................................................................................................2-28 Air Conditioner ..............................................................................................................................2-29 T7 Series Split System Air Conditioning Manual ......................................................................2-29 Section 1.0 Technical Data and Control Settings .....................................................................2-30 Section 2.0 Installation and Commissioning.............................................................................2-32 Section 3.0 Routine Maintenance Procedures .........................................................................2-38 Section 4.0 Fault Diagnosis......................................................................................................2-39 Section 5.0 Reference Drawings ..............................................................................................2-48 Notes ..............................................................................................................................................2-53
Bucyrus International, Inc.® SKSS Introduction Int-6 July, 10 Version 1 Contents 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 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 Repair .......................................................................................................................................3-22 Nitrogen Tensioner ...................................................................................................................3-23 Nitrogen Tensioner – Filling Instructions ..................................................................................3-24 Nitrogen Tensioner – Pressure Check ......................................................................................3-25 Nitrogen Tensioner – Pressure Release ...................................................................................3-25 Hydraulic Tensioner .....................................................................................................................3-26 Hydraulic Tensioner Assembly .................................................................................................3-26 Repair .......................................................................................................................................3-26 Track Chain ...................................................................................................................................3-27 Track Chain – Separate............................................................................................................3-27 Track Chain Repair...................................................................................................................3-28 Track Shoes Installation...............................................................................................................3-30 Track Link Position ...................................................................................................................3-30 Track Shoe – Mounting to Track Chain ....................................................................................3-30
Bucyrus International, Inc.® July, 10 Version 1 Int-7 SKSS Introduction Contents Track Shoe Bolt Torque (Direct Torque Method) .......................................................................3-32 Bolt Torque KN111 ....................................................................................................................3-32 Track Shoe Bolt Torque (Torque Turn Method) .........................................................................3-33 Bolt Torque KN111 ....................................................................................................................3-33 Track Chain and Shoe Installation ..............................................................................................3-34 Track Chain with Shoes............................................................................................................3-34 Track Chain and Shoe – Assembly and Installation .................................................................3-34 Final Drive Unit .............................................................................................................................3-36 General Description..................................................................................................................3-36 Removal from Track Frame ......................................................................................................3-37 Installation into Track Frame ....................................................................................................3-38 Final Drive Maintenance ...........................................................................................................3-39 Final Drive Oil ...........................................................................................................................3-40 F130 Final Drive Assembly.......................................................................................................3-41 Parts List ..................................................................................................................................3-42 F130 Final Drive .......................................................................................................................3-43 General Description..................................................................................................................3-43 Service Information ..................................................................................................................3-44 Tightening Torques ...................................................................................................................3-45 Lubrication / Greasing – Grades and Application Range .........................................................3-45 Planetary Gears F130/206-A....................................................................................................3-46 Troubleshooting ........................................................................................................................3-47 Special Tools ............................................................................................................................3-47 Idler Unit ........................................................................................................................................3-48 Idler Unit – Assembly................................................................................................................3-48 Idler Unit – Removal .................................................................................................................3-51 Track and Support Rollers ...........................................................................................................3-52 Track Roller Assembly ..............................................................................................................3-52 General Description..................................................................................................................3-52 Track Roller – Removal and Disassembly................................................................................3-53 Support Roller – Removal and Disassembly ............................................................................3-53 Track and Support Roller – Assembly ......................................................................................3-54 Track and Support Roller – Test and Install..............................................................................3-55 Track and Sprocket Inspection....................................................................................................3-57 Track Inspection and Wear Limit Guide ...................................................................................3-57 Sprocket Wear Patterns ...........................................................................................................3-61 Notes ..............................................................................................................................................3-67 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 ............................................................................................................................4-8 Cummins Engine ........................................................................................................................4-8 QST30 Electric Fuel Supply System ..........................................................................................4-7 Construction ...............................................................................................................................4-8
Bucyrus International, Inc.® SKSS Introduction Int-8 July, 10 Version 1 Contents 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 Compressor Installation ...............................................................................................................4-31 Safety .......................................................................................................................................4-31 Compressor Assembly .............................................................................................................4-34 Compressor Installation............................................................................................................4-35 Compressor Drive Coupling .....................................................................................................4-36 Compressor Alignment .............................................................................................................4-37 Compressor Shaft Seal ................................................................................................................4-38 Compressor Shaft Seal ............................................................................................................4-38 High Pressure Compressor .........................................................................................................4-41 Description ...............................................................................................................................4-41 Compressed Air Functions .......................................................................................................4-41 Compressor Oil Circuit – 1475cfm @ 500psi ...........................................................................4-45 Compressor Condensation Table .............................................................................................4-48 Compressor Air Circuits – 1475cfm @ 500psi..........................................................................4-49
Bucyrus International, Inc.® July, 10 Version 1 Int-9 SKSS Introduction Contents Compressor Air Circuit Diagram Legend ..................................................................................4-51 Compressor Air Circuit – 1475cfm @ 500psi ..........................................................................4-52 Compressor Functional Description .........................................................................................4-64 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 Scavenge Line..........................................................................................................................4-76 Compressor Discharge Temperature Gauge, Switch and Sender ...........................................4-78 Minimum Pressure / Check Valve ............................................................................................4-79 Minimum Pressure / Check Valve Maintenance .......................................................................4-79 Thermal Bypass Valve ..............................................................................................................4-80 Thermal Bypass Valve Maintenance ........................................................................................4-81 Compressor Fluid Filter ............................................................................................................4-82 Changing Filter Elements .........................................................................................................4-83 Inlet Valve .................................................................................................................................4-84 Relieving Regulators ................................................................................................................4-86 Reducing Regulators ................................................................................................................4-88 System Blowdown Valve ..........................................................................................................4-90 Running Blowdown Valve .........................................................................................................4-91 Running Blowdown Maintenance .............................................................................................4-92 Moisture Separator Maintenance .............................................................................................4-93 Auxiliary Regulator ...................................................................................................................4-93 Auxiliary Regulator Maintenance..............................................................................................4-95 Troubleshooting ........................................................................................................................4-97 System Air Dryer ......................................................................................................................4-99 Airodyn Compressed Air Drain Trap Installation.....................................................................4-100 Airodyn Compressed Air Drain Trap Operation ......................................................................4-100 Airodyn Compressed Air Drain Trap Maintenance .................................................................4-101 Coolers ........................................................................................................................................4-102 Coolers Locator ......................................................................................................................4-102 Hydraulic Oil / Hydraulic Cooler Assembly .............................................................................4-103 Compressor Oil Cooler ...........................................................................................................4-104 Fan Speed ..............................................................................................................................4-104 Engine Cooler / Radiator ........................................................................................................4-105 High Pressure Air to Oil Cooler .................................................................................................4-106 High pressure Air to Oil Cooler – Standard Parts ...................................................................4-106 Removal Replacement ...........................................................................................................4-107 Radiator Cooler ............................................................................................................................4-111 Typical Radiator Core – Standard Parts ..................................................................................4-111 Cleaning ..................................................................................................................................4-112 Tube Removal .........................................................................................................................4-113 Seal Installation .......................................................................................................................4-114 Tube Installation ......................................................................................................................4-115 Notes .............................................................................................................................................4-118
Bucyrus International, Inc.® SKSS Introduction Int-10 July, 10 Version 1 Contents Section 5 - Dust Control System ..................................................... 5-1 Section 5 Contents .........................................................................................................................5-3 Dust Control System ......................................................................................................................5-5 Dust Control Systems .................................................................................................................5-5 Dust Collector Assembly ..........................................................................................................5-10 Fan Wheel .................................................................................................................................5-11 Routine Maintenance ...............................................................................................................5-12 Water Injection ..............................................................................................................................5-13 Water Tanks..............................................................................................................................5-13 Water Injection Pump ...............................................................................................................5-14 Water Injection Relief Valve......................................................................................................5-14 Water Injection Control .............................................................................................................5-15 Water Injection Basic Circuit.....................................................................................................5-16 Water Pump ...................................................................................................................................5-17 Pump Specifications .................................................................................................................5-17 Torque Requirements ...............................................................................................................5-17 Servicing Instructions ...............................................................................................................5-17 Servicing the Plunger Packings................................................................................................5-17 Reassembling Plunger Packings..............................................................................................5-18 Servicing the Pump Valves .......................................................................................................5-18 Reassembling Valve Parts .......................................................................................................5-18 Servicing the Crankshaft ..........................................................................................................5-19 Servicing the Crossheads ........................................................................................................5-19 Water Injection Pump Assembly ...............................................................................................5-20 Replacing Piston Cup Seals .....................................................................................................5-21 Replacing Suction and Discharge Valves .................................................................................5-22 Replacing Power End Bearings................................................................................................5-23 Servicing the Wrist Pin Bearings ..............................................................................................5-24 Fastener Torque Requirements ................................................................................................5-27 Recommended Lubricants .......................................................................................................5-25 Water Pump Motor Repair ........................................................................................................5-25 Water Injection Hydraulic Control Valve Repair........................................................................5-25 Water Pump Drive Coupling .....................................................................................................5-25 Level and Flow Transducer ......................................................................................................5-25 Notes ..............................................................................................................................................5-26 Section 6 - Mast / Rotary Drive / Pipe Rack ................................... 6-1 Section 6 Contents .........................................................................................................................6-3 Mast Weldment................................................................................................................................6-5 Mast Repair ................................................................................................................................6-5 Weld Inspection Schedule .............................................................................................................6-6 Mast Inspection ..........................................................................................................................6-6 Mast Assembly ................................................................................................................................6-7 Mast Assembly 15m ...................................................................................................................6-7 Mast Pivot ...................................................................................................................................6-8 Feed Cylinders ..............................................................................................................................6-10
Bucyrus International, Inc.® July, 10 Version 1 Int-11 SKSS Introduction Contents Feed Cylinders .........................................................................................................................6-10 Removal ...................................................................................................................................6-12 Feed Cylinder Assembly...........................................................................................................6-13 Repair .......................................................................................................................................6-14 Installation ................................................................................................................................6-14 Hoist / Pulldown Cable Adjustment with Auto Tension.............................................................6-15 Hoist / Pulldown Cable Adjustment with Auto Tension Hydraulic .............................................6-15 Hoist / Pulldown Cables ...........................................................................................................6-16 Adjustment ...............................................................................................................................6-17 Replacement ............................................................................................................................6-19 Rotary Drive ..................................................................................................................................6-21 Rotary Head Assembly .............................................................................................................6-21 Rotary Head Guide Alignment ..................................................................................................6-22 Rotary Head – Drive System ....................................................................................................6-24 Rotary Drive – Removal from Mast ..........................................................................................6-25 Rotary Drive – Installation ........................................................................................................6-25 Rotary Drive Gearbox – Repair ................................................................................................6-26 Rotary Head Bull Shaft Bearing Nut .........................................................................................6-27 Manufacturers Recommendations – Blast Hole Drilling Consumables ....................................6-28 Air Swivel ..................................................................................................................................6-29 Winch Assembly ...........................................................................................................................6-30 Precautions on the Use of Winches .........................................................................................6-30 Wire Rope ................................................................................................................................6-30 Wedge Sockets ........................................................................................................................6-32 Grooved Drums ........................................................................................................................6-32 Plain (Smooth) Drums ..............................................................................................................6-33 Drums – Multiple Layers ...........................................................................................................6-33 Winch Assembly Service ..........................................................................................................6-34 BG8A and BG8B Hydraulic Winch Service Manual..................................................................6-35 General Safety Recommendations ....................................................................................6-35 Theory of Operation ...........................................................................................................6-37 Winch Installation ...............................................................................................................6-39 Wire Rope Installation ........................................................................................................6-41 Preventative Maintenance .................................................................................................6-41 071 Motor ...........................................................................................................................6-43 Troubleshooting .................................................................................................................6-44 Disassembly of Winch........................................................................................................6-47 Planetary Carrier Service ...................................................................................................6-49 Motor Support Brake Cylinder Service ..............................................................................6-50 Brake Clutch Service .........................................................................................................6-54 Winch Assembly ................................................................................................................6-56 Brake Valve Service ...........................................................................................................6-59 Reversing Direction of Drum Rotation ...............................................................................6-61 Recommended Fastener Torque .......................................................................................6-62 Deck Wrench .................................................................................................................................6-63 Deck Wrench ............................................................................................................................6-63
Bucyrus International, Inc.® SKSS Introduction Int-12 July, 10 Version 1 Contents H.O.B.O. Wrench ...........................................................................................................................6-64 H.O.B.O Wrench ......................................................................................................................6-64 Breakout System – H.O.B.O ....................................................................................................6-65 Optional Hydraulic Operated Bit Basket – H.O.B.B..................................................................6-65 Pipe Safety Arm........................................................................................................................6-65 Pipe Positioner ..............................................................................................................................6-66 Pipe Positioner .........................................................................................................................6-66 Carousel Pipe Rack ......................................................................................................................6-67 Major Components ...................................................................................................................6-67 Rod Handling – Carousel Indexing...........................................................................................6-68 Pipe Rack Assembly.................................................................................................................6-69 General Information..................................................................................................................6-70 Pipe Rack Bearings – Removal................................................................................................6-70 Pipe Rack Components – Inspection .......................................................................................6-72 Pipe Rack – Assembly and Installation ....................................................................................6-73 Pipe Rack Roller – Remove and Replace ................................................................................6-74 Pipe Rack Roller – Disassembly and Assembly .......................................................................6-75 Top Sub Saver ...............................................................................................................................6-77 Replacement Procedure...........................................................................................................6-77 Notes ..............................................................................................................................................6-78 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
Bucyrus International, Inc.® July, 10 Version 1 Int-13 SKSS Introduction Contents 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 Break Test Procedure SK Infinity Series Drills .........................................................................7-34 Charge Circuit ...............................................................................................................................7-35 Charge Circuit ..........................................................................................................................7-35 Routine Maintenance ...............................................................................................................7-36 Charge Filter ..................................................................................................................................7-37 Changing Filter Elements .........................................................................................................7-37 Main Pumps Circuit ......................................................................................................................7-38 Main Pumps Circuit ..................................................................................................................7-38 Rotation / Tram Motor Circuit ...................................................................................................7-39 Loop Filters ...................................................................................................................................7-40 Loop Filters ...............................................................................................................................7-40 Routine Maintenance ...............................................................................................................7-40 Loop Filter Cross Section .........................................................................................................7-41 Filter Assembly Loop ................................................................................................................7-42 Changing Filter Elements .........................................................................................................7-43 Rotation Circuit .............................................................................................................................7-44 Rotation Circuit .........................................................................................................................7-44 Rotary Drive Gearbox Motor ........................................................................................................7-46 Rotary Drive Gearbox Motor – Test and Repair .......................................................................7-46 Rotary Gearbox Rotation Motor ...............................................................................................7-47 Shaft Seal Replacement...........................................................................................................7-48 Troubleshooting ........................................................................................................................7-49 Tram Circuit ...................................................................................................................................7-51 Tram Circuit ..............................................................................................................................7-51 Main Closed Loop Circuits...........................................................................................................7-53 Diverter Valve ...........................................................................................................................7-53 Operation ..................................................................................................................................7-53 Feed and Auxiliary Pump Circuit .................................................................................................7-54 Hydraulic Piston Pumps – Removal and Replacement ............................................................7-54 Feed and Auxiliary Functions Pump .........................................................................................7-57 Repair Instructions ...................................................................................................................7-58 Pump Replacement – Start Up.................................................................................................7-59 Auxiliary and Feed Circuits .......................................................................................................7-61 Pilot Control Manifold...................................................................................................................7-62 Valve Stand Assembly ..............................................................................................................7-62 Pilot Control Manifold ...............................................................................................................7-63 Pilot Control Manifold Assembly ...............................................................................................7-64 Control Valve Assembly ............................................................................................................7-65 Hydraulic Feed Circuit ..................................................................................................................7-72 Hydraulic Feed Circuit ..............................................................................................................7-72
Bucyrus International, Inc.® SKSS Introduction Int-14 July, 10 Version 1 Contents Directional Control Valve MP22 ................................................................................................7-74 Jack and Mast Raise Valve – MP18 Valve ...............................................................................7-76 Feed Valve Assembly ...................................................................................................................7-78 Feed Valve Assembly ...............................................................................................................7-78 Control Valve Assembly ...............................................................................................................7-80 Technical Data ..........................................................................................................................7-80 Holdback Control ..........................................................................................................................7-82 Holdback Control ......................................................................................................................7-82 Jack Control and Mast Elevating Circuit ....................................................................................7-83 Jack Control and Mast Elevating Control Valve .......................................................................7-83 OEM Controllers / EP Levers ...................................................................................................7-84 Counterbalance Valves ................................................................................................................7-85 Counterbalance Valves Adjustment ..........................................................................................7-85 Levelling Jack Cylinders ..............................................................................................................7-86 Jack Leg Cylinder .....................................................................................................................7-86 Counterbalance Valve Test Procedure .....................................................................................7-86 Mast Elevating Cylinders .............................................................................................................7-87 Mast Elevating Cylinder............................................................................................................7-87 Counterbalance Valve Test Procedure .....................................................................................7-88 Auxiliary Pump Circuit .................................................................................................................7-89 Auxiliary Functions Circuit ........................................................................................................7-89 Auxiliary Pump Circuit ..............................................................................................................7-90 Auxiliary Valves ........................................................................................................................7-91 AWE6 Auxiliary Valves .............................................................................................................7-92 Exploded View ..........................................................................................................................7-94 Hydraulic Operated Breakout Wrench ........................................................................................7-95 H.O.B.O Wrench ......................................................................................................................7-95 H.O.B.O Wrench Circuit ...........................................................................................................7-96 Setting of H.O.B.O Sequence Valves .......................................................................................7-97 H.O B O Float Valve .................................................................................................................7-97 Hydraulic Systems ........................................................................................................................7-98 Pipe Positioner .........................................................................................................................7-98 Pipe Safety Arm........................................................................................................................7-99 Hydraulic Gear Pumps – Removal and Replacement ............................................................7-100 Hydraulic Gear Pumps – Repairs, Operation, Specifications and Adjustment .......................7-100 Hydraulic Gear Pumps – Shaft Seal Removal and Replacement ..........................................7-101 Tool List ..................................................................................................................................7-102 Cooler Fan Circuit .......................................................................................................................7-103 Fan Motor Circuit ....................................................................................................................7-103 Basic Cooler Fan Circuit .........................................................................................................7-105 Cooler Fan Motor ........................................................................................................................7-106 Hydraulic Motor ......................................................................................................................7-106 Cooler Fan Motor Assembly ...................................................................................................7-108 Hydraulic Thermostatic Valve .....................................................................................................7-110 Hydraulic Cooler – Thermal Valve ...........................................................................................7-110 Water Injection Circuit .................................................................................................................7-111
Bucyrus International, Inc.® July, 10 Version 1 Int-15 SKSS Introduction Contents Water Injection.........................................................................................................................7-111 Water Pump Motor .......................................................................................................................7-112 Water Pump Motor Repair Information ....................................................................................7-112 Shaft Seal Repair ....................................................................................................................7-113 Hydraulic Cylinder Repair ...........................................................................................................7-116 Hydraulic Cylinders .................................................................................................................7-116 General Information.................................................................................................................7-117 H Head ....................................................................................................................................7-119 N Head ...................................................................................................................................7-120 Z Head ....................................................................................................................................7-121 Z Head (Two Piece)................................................................................................................7-122 K Head ...................................................................................................................................7-123 M Head ...................................................................................................................................7-124 Z Piston ..................................................................................................................................7-125 Z Piston (Threaded) ...............................................................................................................7-126 H and K Piston .......................................................................................................................7-127 M Piston .................................................................................................................................7-128 N Piston ..................................................................................................................................7-131 Notes ............................................................................................................................................7-132 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 Vigilante Guide ..............................................................................................................................8-13 Important Information ...............................................................................................................8-13 PLC ..........................................................................................................................................8-14 Touchscreen .............................................................................................................................8-17 Laser Depth System .................................................................................................................8-18 Distance Meter .........................................................................................................................8-21 Start Up and Shutdown ............................................................................................................8-21 Alarms ......................................................................................................................................8-22 Solenoid Control .......................................................................................................................8-22 Auto Lube .................................................................................................................................8-25 Hammer Oil System .................................................................................................................8-25 Gauges .....................................................................................................................................8-25 Head Speed Module.................................................................................................................8-27
Bucyrus International, Inc.® SKSS Introduction Int-16 July, 10 Version 1 Contents Level Switches .........................................................................................................................8-27 Dust Suppression .....................................................................................................................8-28 Acknowledgements ..................................................................................................................8-28 Disclaimers ...............................................................................................................................8-29 Notes ..............................................................................................................................................8-30 N.B: For further information on specific electronic components, please refer to Vendor Documents in table of contents on Service Manual CD. 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 Hammer Oil Tank ..........................................................................................................................9-27 Hammer Oiler Tank Assembly ..................................................................................................9-27 Hammer Oil Circuit ...................................................................................................................9-28 10:1 Hammer Oil Pump Instructions ........................................................................................9-29 Installation ................................................................................................................................9-31 Operation ..................................................................................................................................9-34 Troubleshooting ........................................................................................................................9-35 Air Motor and Throat Service ...................................................................................................9-36 Displacement Pump Service ....................................................................................................9-40 Parts List ..................................................................................................................................9-41 Parts Drawing ...........................................................................................................................9-42 Dimensions ...............................................................................................................................9-43 Technical Data ..........................................................................................................................9-43 Performance Chart ...................................................................................................................9-44 Air Service Units ...........................................................................................................................9-45 Air Service Unit System ...........................................................................................................9-45 Soft Start Dump Valve ..............................................................................................................9-46 Filter Regulator .........................................................................................................................9-47 Air Line Oiler .............................................................................................................................9-48 Air Service Unit .........................................................................................................................9-49
Bucyrus International, Inc.® July, 10 Version 1 Int-17 SKSS Introduction Contents Pipe Thread Lubricator ................................................................................................................9-50 Air Operator Pipe Thread Pump ...............................................................................................9-50 Filter Locator .................................................................................................................................9-58 Filter Locator Assembly ............................................................................................................9-58 Lubrication and Preventive Maintenance ...................................................................................9-59 General Lubrication ..................................................................................................................9-59 Equipment Lubrication..............................................................................................................9-59 Care of Lubrication Points ........................................................................................................9-59 Safety .......................................................................................................................................9-60 Track Gear................................................................................................................................9-61 Engine Maintenance.................................................................................................................9-62 Air Cleaners ..............................................................................................................................9-63 Air Filter Elements ....................................................................................................................9-63 Alternator Maintenance ............................................................................................................9-63 Pump Drive and Drive Shaft Maintenance ...............................................................................9-64 Compressor Maintenance ........................................................................................................9-64 Cooler Packs ............................................................................................................................9-64 A-frame and Pivot Point Maintenance ......................................................................................9-66 Pull Down and Hoist Ropes and Sheaves Maintenance ..........................................................9-66 Rotary Head Maintenance........................................................................................................9-66 Hydraulic System Maintenance ................................................................................................9-68 Hydraulic Maintenance .............................................................................................................9-68 Water Pump Maintenance ........................................................................................................9-68 Cab Maintenance .....................................................................................................................9-68 Air Conditioner Maintenance ....................................................................................................9-70 Battery Maintenance ................................................................................................................9-70 Lubrication System Maintenance .............................................................................................9-70 Fire Suppression Maintenance.................................................................................................9-70 Drill Folding Stairway – Inspection Requirements ....................................................................9-72 Weld Inspection Schedule ...........................................................................................................9-73 Weld Inspection Schedule SK Series .......................................................................................9-73 Track and Sprocket Inspection....................................................................................................9-74 Track Inspection and Wear Limit Guide ...................................................................................9-74 Sprocket Wear Patterns ...........................................................................................................9-78 Lubrication Recommendations ...................................................................................................9-84 Lubrication Recommendations .................................................................................................9-84 Lubrication and Maintenance Chart – 250hr ..............................................................................9-85 Lubrication and Maintenance Chart – 500hr ..............................................................................9-95 Lubrication and Maintenance Chart – 1000hr ..........................................................................9-106 Lubrication and Maintenance Chart – 2000hr ...........................................................................9-117 Lubrication and Maintenance Chart ..........................................................................................9-129 Lubrication and Maintenance Notations .................................................................................9-129 Lubricant Specifications ............................................................................................................9-130 Hydraulic System ...................................................................................................................9-130 Hydraulic Tank Capacity .........................................................................................................9-130 Compressor Lubrication .........................................................................................................9-131
Bucyrus International, Inc.® SKSS Introduction Int-18 July, 10 Version 1 Contents Compressor Lubricant Specifications .....................................................................................9-131 Lubricating Grease .................................................................................................................9-132 Gear Lubricant........................................................................................................................9-132 Scheduled Oil Sampling Analysis ...........................................................................................9-132 Torque Values for Split Flange Connections ...........................................................................9-133 Torque Values for Split Flange Connections ..........................................................................9-133 Procedure No. 1-87 Revision A ..............................................................................................9-135 Notes ............................................................................................................................................9-136
General Locator
Mast Clearance Lights Winch
Rotary Head Speed Sensor Rotary Head
Laser for Depth Meter & Pipe in Hole Sensor
General Locator
'Travsafe' Safety Lanyard
Mesh Grating in Mast Floor
Pipe Safety Chain
'Nordic' Hid Light
Two Way & Radio Aerials
Cabin Pressuriser
'Sigma' 7kw Air Conditioner
Rear Dust Skirt Lifter
Dust Skirt
Pneumatically Controlled Access Stairway & Control Box
'Hella' 1067 Worklight
Main Electrical Junction Box
Main Valve Board
Transducer Box
Central Lube Tank Assembly
Hammer Oil Tank Assembly
'Hella' 1067 Worklight
Fire Suppression Tanks
Mast Rest
'Nordic' Hid Light
'Wiggins' Quick Fill Station
Battery Box
Isolation Control Box
Tramming Distance Meter
'Intertrac' B8HD Undercarriage
Bucyrus International, Inc.® July, 10 Version 1 Int-19 SKSS Introduction
General Locator
General Locator (cont.)
Air Receiver Tank
Air Compressor Air Cleaners (Under Mast Access Platform)
Emergency Ladder
Mast Access
'Sullair' Air Compressor
Muffler
Engine Radiator Hydraulic Oil Cooler
CCTV Camera
'AFFF' Fire Suppression System Tanks
'Wiggins' Service Centre
Engine Air Filters
Emergency Ladder
Central Lube Tank Assembly
Hammer Oil Tank Assembly
Compressor Oil Cooler
Muffler
Transducer Box
Hydraulic Tank
'Funk' Pump Drive
Mast Elevating Cylinders
Tool Box
Emergency Ladder
Handrailing to Australian Standards
'Nordic' Hid Light
Viewing Hatch
Extinguisher
Main Hydraulic Valve Board
Main Electrical Junction Box
Pneumatically Controlled Access Stairway & Control Box
Boot Cleaner
7kw Air Conditioner & Pressuriser
Operator's Cabin
Flashing Beacon
Bucyrus International, Inc.® SKSS Introduction Int-20 July, 10 Version 1
Bucyrus International, Inc.® July, 10 Version 1 Int-21 SKSS Introduction Notes
Bucyrus International, Inc.® SKSS Introduction Int-22 July, 10 Version 1 Notes
Section 1 Safety
Bucyrus International, Inc.®
Safety June, 10 Version 1 1-1 SKS-W Safety
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