CAT BUCYRUS SKF-12 Infinity Blasthole Drill Service Manual SN 1K68X49 – PDF DOWNLOAD by www.heydownloads.com

Technical Manual

BI620404

BUCYRUS

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Think Terex, Think Integrity SKF-12 Infinity Blasthole Drill

No.1K68X49 Service Manual SERVICE MANUAL PART NO. 91-A11-627 October 2009, Version 1 BI620404

Serial

BI620404

Use only genuine Terex Reedrill parts in the maintenance, rebuild, or repair, of Terex Reedrill machines. Terex Reedrill shall have no liability as to any unauthorised modiﬁcation of machines or parts and shall have no obligation or liability as to any machines or parts which have been improperly handled, or which have not been operated, maintained, or repaired according to Reedrill’s furnished manuals, or other written instructions, or which are operated with other than genuine Reedrill parts.

Effective Date: August, 2007. Product speciﬁcations and prices are subject to change without notice or obligation. The photographs and/or drawings in this document are for illustrative purposes only. Refer to the appropriate Operator’s Manual for instructions on the proper use of this equipment. Failure to follow the appropriate Operator’s Manual when using our equipment or to otherwise act irresponsibly may result in serious injury or death. The only warranty applicable to our equipment is the standard written warranty applicable to the particular product and sale and Terex makes no other warranty, express or implied. Products and services listed may be trademarks, service marks or trade-names of Terex Corporation and/or its subsidiaries in the USA and other countries. All rights are reserved. Terex® is a registered trademark of Terex Corporation in the USA and many other countries. Copyright (or ©) 2007 Terex Corporation.

Your co-operation in furnishing as much information as possible will assist us in ﬁlling your orders correctly and in the shortest possible time.

1. IDENTIFICATION OF THE MACHINE

Always furnish the Reedrill Model Number and Serial Number when ordering parts. This information is found on the machine nameplate.

2. PART NUMBER AND DESCRIPTION

In addition to the Serial Number, always give the part number and description of each part ordered. If there is any doubt as to the correct part number and description, furnish a dimensioned sketch or return the part to be replaced, transportation charges prepaid.

3. SHIPMENT

Unless otherwise instructed, all shipments will be made via road freight and charged on our invoice. Shipments cannot be made on open account until your credit has been approved by our Accounting Department.

MAILING ADDRESSFOR PARTS ORDER ENTRYSHIPPING ADDRESS Terex WA Telephone 1300 883 677 Terex WA 2 Reid Road Fax 1300 883 577 2 Reid Road Perth Int. Airport WA 6105 Perth Int. Airport WA 6105 Ph (08) 9373 6000 Fax (08) 9373 6173 AUSTRALIAN BRANCHES Brisbane Newcastle Mackay 33 Kimberley St 139 Racecourse Rd 10-12 Corporate Dve Darra QLD 4076 Rutherford NSW 2320 Mackay QLD 4740 Ph. (07) 3456 4500 Ph. (02) 4932 0000 Ph (07) 4952 0600 Fax. (07) 3456 4534 Fax (02) 4932 0733 Fax (07) 4952 0666 © TEREX 2007

SKF Introduction Int-3 Contents Parts

Product Support BI620404

Parts Ordering and Product Support

Ordering and

Safety Information

This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury or property damage.

WARNING: BEFORE STARTING ENGINE: Study Operator and Service Manuals

• Study Engine Operator and Maintenance Manual

• Practice All Safety Precautions

• Make Pre-Operation Check

•

• Learn Controls Before Operating

WARNING: DO NOT use this machine for any other purpose than blasthole drilling. The Inﬁnity Series rotary blasthole drill is designed for blasthole drilling purposes only. Any other use could result in personal injury and/or property damage and will void the warranty.

CAUTION: Each person performing service work must be satisﬁed that they have adequate knowledge and training to perform the required tasks. A thorough understanding of hydraulic and pneumatic systems as well as electrical and mechanical knowledge and experience is required.

This manual is furnished with your Infinity Series rotary blasthole drill to aid you in performing the necessary service work to maintain your drill in good operating condition. This manual contains repair and adjustment information for all major operating systems on the machine. In some cases such as hydraulic pumps and motors it is better to replace the unit with a new or rebuilt unit than to perform major repairs. Should further information be desired or should particular problems arise which are not covered sufficiently in this manual, the matter should be referred to manufacturer.

The descriptions and speciﬁcations contained in this manual were in effect at the time of printing. The right is reserved to make changes at any time without notice and without obligation.

It is YOUR responsibility to understand and follow manufacturer's instructions on machine operation and service, and to observe pertinent safety precautions, laws and regulations. Failure to read and understand this manual and all safety, capacity and instruction placards on the machine before operating the unit, constitutes a misuse of the machine. It is your responsibility to know the manufacturer's specific requirements, government regulations, required precautions and any work hazards which may exist. You must make these known to all personnel working with the equipment or in the area, so that all may take the necessary and required safety precautions. Keep all children, visitors, and untrained personnel away from the equipment. It is also your responsibility to operate your equipment with skill, good judgment, and caution. Following recognised safety procedures will help you avoid accidents. Failure to heed these instructions can result in property damage, serious injury or death.

Drill Model: _____________________________________________________________________

Drill Serial No.: _____________________________________________________________________

Date Delivered: _____________________________________________________________________

Dealer: _____________________________________________________________________

Customer: _____________________________________________________________________

Int-4 SKF Introduction Contents Safety Information BI620404

SKF Introduction Int-5 Contents Section 1 - Safety..............................................................................1-1 Section 1 Contents .........................................................................................................................1-3 Safety ...............................................................................................................................................1-5 Personal Protective Equipment 1-5 Noise 1-5 Electrical Contact ....................................................................................................................... 1-5 Overhead and Buried Utilities..................................................................................................... 1-5 Contact with Electric Wires 1-6 Contaminated Air 1-6 Machine Stability 1-7 Moving and Rotating Parts 1-8 High Pressure Air or Fluid .......................................................................................................... 1-8 Before Operation 1-8 During Operation 1-9 Maintenance 1-11 Safety Locator 1-12 Notes ..............................................................................................................................................1-14 Section 2 - Operator's Cab / Controls .............................................2-1 Section 2 Contents .........................................................................................................................2-3 Graphic Symbol Legend ................................................................................................................2-4 Warning Decals ...............................................................................................................................2-8 Operators Controls and Indicators .............................................................................................2-10 Operators Control Panels ......................................................................................................... 2-10 System Pressure Gauge Panel 2-13 Switch Panel 2-14 Switches / Diagnosis Control Panel 2-17 Cab Heater .....................................................................................................................................2-18 Cab Heater Fault Isolation........................................................................................................ 2-18 Air Conditioner ..............................................................................................................................2-19 TDR7BX1 Packaged Unit Manual 2-19 Section 1.0 – Introduction 2-21 Section 2.0 – Unit Specification and Settings 2-22 Section 3.0 – Technical Data and Control Settings .................................................................. 2-27 Section 4.0 – Installation and Commissioning.......................................................................... 2-29 Section 5.0 – Operating Instructions 2-41 Section 6.0 – Routine Maintenance Procedures 2-43 Section 7.0 – Fault Diagnosis 2-49 Section 8.0 Warranty 2-60 Electrical Schematic ................................................................................................................. 2-61 Notes ..............................................................................................................................................2-63 Section 3 - Main Frame / Crawlers ..................................................3-1 Section 3 Contents .........................................................................................................................3-3 Main Frame Repair – General ........................................................................................................3-5 Main Frame Repair ..................................................................................................................... 3-5 BI620404

Int-6 SKF Introduction Contents Weld Inspection Schedule .............................................................................................................3-6 Main Frame ................................................................................................................................ 3-6 Levelling Jacks ...............................................................................................................................3-7 Levelling Jacks 3-8 Levelling Jack Cylinders 3-8 Lubricating Jack Casings 3-8 Mast Elevating Cylinders ...............................................................................................................3-9 Mast Elevating Cylinders 3-9 Crawler Assembly .........................................................................................................................3-10 Crawler Assembly 3-10 Crawler Component Repair 3-10 Metric Bolt Torque Specifications ................................................................................................3-11 Track Maintenance........................................................................................................................3-12 Before Operating the Machine 3-12 General Maintenance 3-12 Track Tension Adjustment ...........................................................................................................3-13 Track Chain ...................................................................................................................................3-15 Separate Track Chain Assembly .............................................................................................. 3-15 Track Link – Repair and Replace 3-16 Track Shoes...................................................................................................................................3-18 Track Link Position 3-18 Track Shoe – Mounting to Tracks Chain 3-18 Track Shoe Bolt Torque (Direct Torque Method) .......................................................................3-20 Bolt Torque KN111 .................................................................................................................... 3-20 Track Shoe Bolt Torque (Torque Turn Method) .........................................................................3-21 Bolt Torque KN111 3-21 Track Chain and Shoe Installation ..............................................................................................3-22 Track Chain with Shoes............................................................................................................ 3-22 Track Chain and Shoe – Assembly and Installation ................................................................. 3-22 Final Drive .....................................................................................................................................3-24 General Description 3-24 Removal from Track Frame 3-25 Installation into Track Frame 3-26 Oil Check Charge ..................................................................................................................... 3-27 Final Drive Oil ................................................................................................................................3-28 Specifications 3-28 Recommended Oils 3-28 Final Drive Assembly ....................................................................................................................3-30 Final Drive Assembly ................................................................................................................ 3-30 Parking Brake – Description ..................................................................................................... 3-32 Parking Brake – Removal and Installations 3-33 Towing Procedures – Gear Drive Disconnect 3-33 Repair Manual Final Drive Model F100 3-34 A – General Instructions ........................................................................................................... 3-34 B – Safety Instructions ............................................................................................................. 3-39 C – General Specifications 3-43 BI620404

SKF Introduction Int-7 Contents D – Disassembly and Assembly Operation .............................................................................. 3-52 E – Troubleshooting ................................................................................................................. 3-86 F – Special Tools ...................................................................................................................... 3-87 Idler Unit ........................................................................................................................................3-88 General Description 3-88 Removal and Disassembly 3-90 Assembly and Installation 3-92 Track Tension Unit ........................................................................................................................3-94 Installation 3-95 Track Rollers .................................................................................................................................3-96 General Description 3-96 Track Roller Assembly 3-97 Auxiliary Crane .............................................................................................................................3-98 Palfinger Hydraulic Crane PC1300 Operators Manual 3-98 Possible Dangers ............................................................................................................... 3-99 During Operation of the Crane ......................................................................................... 3-100 Visual Inspections ............................................................................................................ 3-102 Survey of the Crane ......................................................................................................... 3-103 During Operation of the Crane ......................................................................................... 3-105 Safety Devices 3-108 Optional Features 3-111 Maintenance 3-112 Cleaning the Crane 3-118 PC1300 Specifications 3-118 Remote Winch Pendant 3-123 Notes ............................................................................................................................................3-124 Section 4 - Engine / Drive Train / Compressor...............................4-1 Section 4 Contents .........................................................................................................................4-3 Engine and Drive Train Service Procedures ................................................................................4-5 Service Procedures Outlined on the Section Include 4-5 Power Train 4-5 Engine Service Procedures 4-5 Caterpillar 3412E Engine ........................................................................................................... 4-6 Engine and Compressor Air Cleaner .......................................................................................... 4-7 Engine and Compressor Air Cleaner ............................................................................................4-8 Engine and Compressor Air Cleaner Service 4-8 Flexible Drive Coupling .................................................................................................................4-11 Flexible Drive Coupling Service ................................................................................................ 4-11 Pump Drive ....................................................................................................................................4-13 Pump Drive Assembly – Removal and Replacement 4-13 Pump Drive Gearbox ....................................................................................................................4-14 Pump Drive Gearbox – Repair 4-14 Hydraulic Pumps ..........................................................................................................................4-16 Hydraulic Pump Identification ................................................................................................... 4-16 Hydraulic Pump Removal and Replacement............................................................................ 4-17 BI620404

Int-8 SKF Introduction Contents Compressor Service Procedures ................................................................................................4-18 Compressor Drive Coupling ..................................................................................................... 4-18 Compressor Drive Coupling – Removal and Replacement 4-18 Mounting Instructions for ARCUSFLEX™ Flywheel Couplings 4-19 Taper-Loc Bushing Installation 4-20 Tightening Torques for ARCUSFLEX™ Flywheel Coupling 4-20 Before Installation and Start-up of New or Rebuilt Compressor 4-21 Compressor Unit Installation 4-21 Compressor Shaft Seal ................................................................................................................4-22 High Pressure Compressor .........................................................................................................4-25 Safety 4-25 Description 4-28 Compressed Air Functions 4-28 Compressor Oil Circuit ................................................................................................................4-32 Compressor Oil Circuit 4-32 Compressor Oil Circuit – 1150cfm @ 350psi ........................................................................... 4-32 Compressor Condensation Table ...............................................................................................4-34 Compressor Functional Description ...........................................................................................4-35 Compressor Operation .................................................................................................................4-38 Operation .................................................................................................................................. 4-38 Compressor Air Circuit – 1150cfm @ 350psi ............................................................................ 4-41 Initial Start-up Procedure.......................................................................................................... 4-42 Compressor Maintenance ............................................................................................................4-44 General Maintenance 4-44 Interstage Tube 4-46 Discharge Check Valve 4-47 Separator / Receiver Elements 4-48 Scavenge Line 4-50 Compressor Discharge Temperature Gauge, Switch and Sender 4-51 Minimum Pressure / Check Valve 4-52 Minimum Pressure / Check Valve Maintenance 4-52 Thermal Bypass Valve 4-53 Thermal Bypass Valve Maintenance 4-54 Compressor Fluid Filter 4-55 Changing Filter Elements 4-55 Fluid Stop Valve ....................................................................................................................... 4-57 Inlet Valve ................................................................................................................................. 4-59 Relieving Regulators ................................................................................................................ 4-61 Reducing Regulators ................................................................................................................ 4-63 Reducing Regulator Maintenance ............................................................................................ 4-64 System Blowdown Valve .......................................................................................................... 4-66 Running Blowdown Valve ......................................................................................................... 4-67 Running Blowdown Maintenance 4-68 Moisture Separator Maintenance 4-69 Troubleshooting 4-70 BI620404

SKF Introduction Int-9 Contents Fan / Oil Cooler Piping .................................................................................................................4-72 Fan / Oil Cooler Piping ............................................................................................................. 4-72 Fan and Motor Installation 4-73 Compressor Oil / Hydraulic Oil Cooler Service Manual ............................................................4-74 Standard Parts – High Pressure Oil Coolers 4-74 Repair Instruction – External Cleaning and Tube Removal 4-75 Repair Instruction – Seal Removal, Heater Plate Preparation and Seal Installation 4-76 Repair Instruction – Tube Installation, Final Assembly and Testing 4-77 Repair Instruction – Special Header Plate Repair 4-78 Radiator / Oil Cooler Repair .........................................................................................................4-79 Radiator Cooler Service Manual ..................................................................................................4-80 Typical Radiator Core – Standard Parts 4-80 Cleaning 4-81 Tube Removal 4-81 Seal Installation 4-82 Tube Installation ....................................................................................................................... 4-83 Notes ..............................................................................................................................................4-85 Section 5 - Dust Control System .....................................................5-1 Section 5 Contents .........................................................................................................................5-3 Dust Control System ......................................................................................................................5-5 Dust Control Systems 5-5 Water Injection ................................................................................................................................5-6 Pressure Adjustment 5-6 Water injection Circuit................................................................................................................. 5-7 Basic Water Injection System ..................................................................................................... 5-8 Water Pump .....................................................................................................................................5-9 Pump Specifications 5-9 Servicing Instructions 5-9 Water Injection Pump and Parts List 5-10 Replacing Piston Cup Seals 5-11 Replacing Suction and Discharge Valves ................................................................................. 5-12 Replacing Power End Bearings................................................................................................ 5-13 Servicing the Wrist Pin Bearings 5-14 Fastener Torque Requirements 5-14 Recommended Lubricants 5-15 Water Pump Motor Repair 5-15 Water Injection Hydraulic Control Valve Repair........................................................................ 5-15 Water Pump Drive Coupling ..................................................................................................... 5-15 Level and Flow Transducer 5-15 Water Pump Motor ........................................................................................................................5-16 Char-Lynn® Hydraulic Motor Manual – 'H' Series 5-16 Tools Required for Disassembly and Reassembly 5-17 Shaft Seal Repair ..................................................................................................................... 5-18 Notes ..............................................................................................................................................5-21 BI620404

Int-10 SKF Introduction Contents Section 6 - Mast / Rotary Drive / Pipe Rack....................................6-1 Section 6 Contents .........................................................................................................................6-3 Mast Weldment................................................................................................................................6-5 Mast Repair 6-5 Weld Inspection Schedule .............................................................................................................6-6 Inspection Mast 6-6 Mast Assembly ................................................................................................................................6-7 Mast Assembly 12m 6-7 Mast Pivot Caps 6-8 Mast Elevate Cylinders 6-8 Angle Drilling 6-9 Feed Cylinders ..............................................................................................................................6-10 SKF 12 Feed System 6-10 Feed Cylinder – Removal 6-11 SKF-12 Feed Cylinder 6-12 Repair 6-13 Installation ................................................................................................................................ 6-13 Hoist / Pulldown Cable .................................................................................................................6-14 Auto Tensioning – Operating Principle ..................................................................................... 6-15 Auto Tensioning – Cable Removal, Adjustment and Installation .............................................. 6-15 Rope Tensioning Circuit ........................................................................................................... 6-17 Wire Rope ................................................................................................................................ 6-19 Sleave Rollers .......................................................................................................................... 6-19 Rotary Head Guide Alignment .....................................................................................................6-20 Alignment Procedure 6-20 Rotary Drive Assembly .................................................................................................................6-21 Rotary Drive Assembly 6-21 Rotary Drive – Removal from Mast 6-22 Rotary Drive – Installation 6-22 Rotary Drive Gearbox ...................................................................................................................6-23 Single Motor Rotary Drive Gearbox 6-23 Air Swivel (Dual Seal Style) 6-25 Service 6-25 Rotary Drive Motor – Repair 6-26 Top Mast Drive Transmission TM2132-4 Manual 6-27 Preface...............................................................................................................................6-28 General Working Instructions.............................................................................................6-29 Work Safety .......................................................................................................................6-30 Symbol Explanation ...........................................................................................................6-30 Conversion Table ...............................................................................................................6-31 Torque Limit Table Grade 5 UNC .......................................................................................6-32 Torque Limit Table Grade 5 UNF .......................................................................................6-33 Torque Limit Table Grade 8 UNC .......................................................................................6-34 Torque Limit Table Grade 8 UNF .......................................................................................6-35 Inscription of the Model Identification Plate .......................................................................6-36 BI620404

SKF Introduction Int-11 Contents Disassembly Transmission ................................................................................................6-37 Assembly Transmission .....................................................................................................6-44 Rotary Drive Motor .......................................................................................................................6-62 Rotary Drive Motor .............................................................................................................6-62 Winch Assembly ...........................................................................................................................6-63 Precautions on the use of Winches .......................................................................................... 6-63 Wire Rope 6-63 Wedge Socket 6-65 Grooved Drums ........................................................................................................................ 6-65 Plain (Smooth) Drums 6-66 Drums - Multiple Layers 6-66 Winch Assembly Service .......................................................................................................... 6-67 BG8A and BG8B Hydraulic Winch Manual 6-68 Forward ..............................................................................................................................6-69 Explanation of Model Number ...........................................................................................6-69 Theory of Operation ...........................................................................................................6-70 Winch Installation ...............................................................................................................6-72 Wire Rope Installation ........................................................................................................6-73 Preventative Maintenance .................................................................................................6-74 071 Motor ...........................................................................................................................6-75 Troubleshooting .................................................................................................................6-76 Disassembly of Winch........................................................................................................6-80 Planetary Carrier Service ...................................................................................................6-82 Motor Support Brake Cylinder Service ..............................................................................6-84 Brake Clutch Service .........................................................................................................6-88 Winch Assembly ................................................................................................................6-90 Brake Valve Service ...........................................................................................................6-92 Reversing Direction of Drum Rotation ...............................................................................6-94 Recommended Fastener Torque .......................................................................................6-95 Metric Conversion Table ....................................................................................................6-96 H.O.B.O Wrench ............................................................................................................................6-97 Tong Dies 6-98 Deck Wrench .................................................................................................................................6-99 Pipe Positioner ............................................................................................................................6-100 Pipe Positioner .......................................................................................................................6-100 Carousel Pipe Rack ....................................................................................................................6-101 If Pipe Rack Does Not Rotate 6-101 Chain Drive – Adjust / Replace............................................................................................... 6-101 Pipe Rack Bearings - Replace 6-102 Carousel Top Tube Bearing – Replace 6-103 Carousel Lower Bearing – Replace........................................................................................ 6-105 Carousel Pivot Support Upper Bearing – Replace 6-107 Carousel Pivot Support Lower Bearing – Replace 6-109 Mid Point Carousel Pivot Support ........................................................................................... 6-110 Carousel Rotate Motor 6-110 Notes .............................................................................................................................................6-111 BI620404

Int-12 SKF Introduction Contents Section 7 - Hydraulic Systems ........................................................7-1 Section 7 Contents .........................................................................................................................7-3 Hydraulic Symbols .........................................................................................................................7-7 Hydraulic Tank ................................................................................................................................7-9 Hydraulic Tank 7-10 Hydraulic System 7-10 Pressure Setting Sequence ....................................................................................................7-11 Pressure Setting Sequence 7-11 Hydraulic System 7-11 Main Return and Case Drain Filter ..............................................................................................7-12 Routine Maintenance ............................................................................................................... 7-13 Changing Filter Elements ......................................................................................................... 7-13 Main Hydraulic Pumps .................................................................................................................7-14 Hydraulic Pump Identification ................................................................................................... 7-14 Right Track / Pulldown, Left Track / Rotation Pumps ...............................................................7-15 Hydraulic Piston Pumps – Removal and Replacement 7-15 Main Pumps 7-16 AA4VG 125 Hydraulic Pump EP2 Control 7-16 AA4VG EP Controller 7-18 Technical Data 7-19 EP (24V DC) Control 7-21 Schematic Drawing – Standard Model 7-21 Technical Data 7-22 Port Locations 7-24 Connections 7-24 Main Pump Adjustments 7-25 Set Charge Pressure 450psi (31bar) 7-27 Set Pressure Override 5000psi (38bar) 7-27 Set Pressure Override (P.O.R) – 5000psi (345bar) 7-28 Mechanical Zero Position ......................................................................................................... 7-29 Hydraulic Piston Pumps – Maintenance .....................................................................................7-30 Hydraulic Centreing .................................................................................................................. 7-30 Removal and Inspection of Charge Pump................................................................................ 7-31 Hydraulic Piston Pumps – Troubleshooting ..............................................................................7-32 Removal and Installation of Shaft Seal .................................................................................... 7-32 Routine Maintenance 7-33 Charge Circuit ...............................................................................................................................7-38 Double Gear Pump – Right Charge and Water Injection.......................................................... 7-38 Charge Circuit Schematic 7-39 Routine Maintenance 7-41 Changing Filter Elements 7-41 Loop Filters ...................................................................................................................................7-42 Loop Filters 7-42 Routine Maintenance 7-45 Changing Filter Elements 7-45 BI620404

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SKF Introduction Int-13 Contents Diverter Valve ................................................................................................................................7-46 Diverter Valve ........................................................................................................................... 7-46 Operation 7-46 Diverter Valve 7-46 Hydraulic Feed and Rotation Circuit ...........................................................................................7-47 Basic Left Track / Rotation Pump Circuit 7-47 Basic Left Track / Rotation Pump ............................................................................................. 7-47 Rotation Circuit 7-48 Basic Right Track / Pulldown and Hoist Circuit 7-49 Basic Right Track / Pulldown and Hoist 7-49 Hoist / Pulldown Circuit 7-50 Drill / Tram Control Circuit ...........................................................................................................7-51 Operation .................................................................................................................................. 7-51 Rope Tensioning Circuit ..............................................................................................................7-54 Auto Tensioning – Operating Principle 7-54 Rotary Drive Gearbox Motor ........................................................................................................7-55 Variable Displacement Motor AA6VM ...................................................................................... 7-55 Rotation Motor .......................................................................................................................... 7-59 Fan and Auxiliary Pump Circuit ...................................................................................................7-89 Hydraulic Pump Identification 7-89 Fan and Auxiliary Functions Pump 7-71 Hydraulic Pumps ..........................................................................................................................7-72 Hydraulic Piston Pumps – Removal and Replacement ............................................................ 7-72 Model A11VLO Hydraulic Piston Pumps - Repair .................................................................... 7-72 Repair Instructions 7-73 New or Rebuilt Hydraulic Pump – Start-up ................................................................................7-74 Start-up Procedure 7-74 Auxiliary Functions / Fan Circuit .................................................................................................7-76 Operation .................................................................................................................................. 7-77 Auxiliary Functions / Fan Circuit 7-79 Auxiliary Fan Circuit 7-81 Auxiliary Priority Function 7-82 Cooler Fan Circuit .........................................................................................................................7-83 Cooler Fan Circuit .................................................................................................................... 7-83 Cooler Fan Motor ..........................................................................................................................7-85 Hydraulic Motor F12 Series Service Manual 7-85 Specification and Tools 7-86 Hydraulic Motor F12 Series 7-88 Jack and Mast Elevate Circuit .....................................................................................................7-89 4 Bank Valve ............................................................................................................................ 7-89 Counterbalance Valve Adjustment ..............................................................................................7-91 Counterbalance Valve Adjustments 7-91 Mast Elevating Cylinders .............................................................................................................7-92 Mast Elevating Cylinders Counterbalance Valves .................................................................... 7-92 Levelling Jack Cylinders ..............................................................................................................7-93 Jack Counterbalance Valves 7-93 BI620404

Int-14 SKF Introduction Contents Auxiliary Functions / 6 Bank Valve .............................................................................................7-94 Auxiliary Functions / 9 Bank Valve .............................................................................................7-95 Hydraulic Operated Breakout Wrench (HOBO) ..........................................................................7-96 Setting of Sequence Valves 7-96 Carousel Rotate Motor .................................................................................................................7-97 2000 Series Disc Valve Geroler Motor Repair Information 7-97 Disassembly ............................................................................................................................. 7-99 Reassembly 7-101 Pilot Control Manifold.................................................................................................................7-104 Hydraulic Gear Pumps ................................................................................................................7-118 Hydraulic Gear Pumps – Removal and Replacement 7-118 Hydraulic Gear Pump – Repair ............................................................................................... 7-118 Hydraulic Gear Pumps – Shaft Seal Removal and Replacement ........................................... 7-119 Tool List 7-120 Dust Collector / Water Injection Circuit ....................................................................................7-121 Pressure Adjustment 7-121 Dust Collector / Water Injection Circuit ................................................................................... 7-122 Hydraulic Cylinder Repair ..........................................................................................................7-123 General Information 7-124 H Head 7-126 N Head 7-127 Z Head 7-128 Z Head (Two Piece)................................................................................................................ 7-129 K Head ................................................................................................................................... 7-130 M Head 7-131 Z Piston 7-132 H and K Piston 7-133 M Piston ................................................................................................................................. 7-134 N Piston .................................................................................................................................. 7-137 Notes ............................................................................................................................................7-138 Section 8 - Electrical Components .................................................8-1 Section 8 Contents .........................................................................................................................8-3 Electrical Locator ............................................................................................................................8-5 Electrical Locator ........................................................................................................................ 8-5 Jump Starting ..................................................................................................................................8-7 Batteries ..........................................................................................................................................8-9 Electrical Components .................................................................................................................8-10 Electrical Circuits ...................................................................................................................... 8-10 Transducers.............................................................................................................................. 8-10 Joystick Adjustments 8-12 Welding Precautions ....................................................................................................................8-14 Vigilante Guide ..............................................................................................................................8-15 Important Information 8-15 PLC .......................................................................................................................................... 8-16 Touchscreen ............................................................................................................................. 8-19 BI620404

SKF Introduction Int-15 Contents Laser Depth System ................................................................................................................. 8-20 Start Up and Shut Down........................................................................................................... 8-22 Alarms 8-23 Solenoid Control 8-24 Auto Lube 8-26 Hammer Oil System 8-26 Gauges ..................................................................................................................................... 8-27 Dust Suppression 8-27 Important Information 8-28 Disclaimers 8-28 Vigilante System Component Information .................................................................................8-29 Ladder Prox Switch .................................................................................................................. 8-29 Jacks Prox Switch .................................................................................................................... 8-29 LDM 40 A Laser 8-30 General 8-30 Safety Instructions 8-31 Performance Data .................................................................................................................... 8-32 Working Principle ..................................................................................................................... 8-33 Setup 8-33 Interface Cable Wire Assignment 8-34 Limiting Values for Voltages 8-35 Starting Up 8-35 Parameters ............................................................................................................................... 8-36 Functions .................................................................................................................................. 8-39 Service, Maintenance, Warranty 8-41 Radiator Level Switch 8-42 Hammer Oil Level Transducer 8-46 Pressure Transducers – Combined Pressure Sensor .............................................................. 8-48 Access Light Timer ................................................................................................................... 8-57 Rod Counter Prox Switch 8-58 Cat 3412E Flash Codes 8-59 Cat 3412E Electrical System 8-61 Cat 3412E Sensor Layout 8-62 Cat 3412E Sensor Schematic .................................................................................................. 8-66 Notes ................................................................................................................................................8-6 Section 9 - Lubrication and Preventive Maintenance ...................9-1 Section 9 Contents .........................................................................................................................9-3 Central Lube System ......................................................................................................................9-5 Description ................................................................................................................................. 9-5 Auto Lube 9-5 Auto Lube Lincoln Pneumatic Pump Owners Manual 9-6 SL-1 Injectors 9-15 SL-1 Injectors Assembly 9-15 SL-1 Injectors Specifications .................................................................................................... 9-15 SL-1 Injectors Operations 9-16 BI620404

Int-16 SKF Introduction Contents Filter / Regulator / Lubricator .................................................................................................... 9-17 Filter Maintenance and Repair ................................................................................................. 9-18 Lubrication Maintenance and Repair 9-20 Air Service Units ...........................................................................................................................9-21 Filter Regulator 9-21 Air Oil Oiler 9-22 Pipe Thread Lubricator ................................................................................................................9-23 Air Service Unit 9-23 Air Operated Pipe Thread Pump 9-24 Hammer Oil System ......................................................................................................................9-32 Hammer Oiler Tank Assembly 9-32 Hammer Oil Circuit ................................................................................................................... 9-33 Air Service Unit Components ................................................................................................... 9-34 Filter Regulator 9-35 Air Line Oiler 9-36 10:1 Hammer Oil Pump Manual 9-37 Symbols .............................................................................................................................9-38 Installation ..........................................................................................................................9-40 Operation ...........................................................................................................................9-43 Air Motor and Throat Service .............................................................................................9-45 Displacement Pump Service ..............................................................................................9-49 Dimensions ........................................................................................................................9-50 Technical Data ...................................................................................................................9-50 Performance Data ..............................................................................................................9-51 Lubrication General ......................................................................................................................9-52 Equipment Lubrication 9-52 Care of Lubrication Points 9-52 Lubrication and Preventive Maintenance ...................................................................................9-53 Safety ....................................................................................................................................... 9-53 Isolation – Battery Switch 9-54 Track – Check and Lubrication 9-55 Engine Maintenance 9-56 Air Cleaners 9-57 Air Filter Elements .................................................................................................................... 9-57 Alternator Maintenance 9-57 Compressor – Checks and Servicing 9-58 Air Conditioner – Checks and Servicing 9-59 Drive Shaft – Checks and Maintenance 9-59 Cooler – Checks and Servicing ................................................................................................ 9-60 Hydraulic – Checks and Servicing............................................................................................ 9-61 A-frame and Mast Pivot Point – Checks and Maintenance 9-62 Rotary Head – Checks and Service Points 9-63 Pulldown / Hoist Sheaves and Ropes – Checks and Servicing 9-64 Cabin – Checks and Service Points ......................................................................................... 9-65 Fire Suppression (Optional) – Checks and Servicing............................................................... 9-65 Battery – Checks and Servicing 9-66 BI620404

SKF Introduction Int-17 Contents Bean Pump – Checks and Maintenance .................................................................................. 9-66 Lubrication System – Checks and Servicing ............................................................................ 9-67 Weld Inspection Schedule ...........................................................................................................9-68 Weld Inspection Schedule SK Series 9-68 250hr Lubrication and Maintenance ...........................................................................................9-69 500hr Lubrication and Maintenance ...........................................................................................9-84 1000hr Lubrication and Maintenance .......................................................................................9-100 2000hr Lubrication and Maintenance ........................................................................................9-116 Lubricant Specifications ............................................................................................................9-134 Equipment Lubrication 9-134 Care of Lubrication Points 9-134 Compressor Lubrication Procedure........................................................................................ 9-134 Winch Assembly Lubrication (Braden BG-8H) ....................................................................... 9-134 Compressor 9-135 Lubricating Grease 9-135 Gear Lubricant 9-135 Hydraulic System ................................................................................................................... 9-136 Hydraulic Tank Capacity ......................................................................................................... 9-136 Hydraulic System Maintenance 9-137 Cooling System Maintenance 9-137 Cooling System Freeze Protection 9-138 Air Cleaner 9-138 Air Filter Elements .................................................................................................................. 9-138 Electrical System .................................................................................................................... 9-138 Schedule Oil Sampling Analysis 9-139 Torque Values for Split Flange Connections ...........................................................................9-140 Procedure No. 1-87 Revision A 9-140 Torque Values for Split Flange Connections .......................................................................... 9-141 Notes ............................................................................................................................................9-143 BI620404

General Locator

ROTARYDRIVE

COTTONREEL

CRANECONTROLS

OPERATORSCABIN

A/CPRESSURISER

CABAIRCONDITIONER

FIRESUPPRESSION ACTUACTOR

E/STOP

TRANSDUCERBOX

MAINELECTRICALCABINET

HYDTANK

MASTRAISECYLINDER

FIRESUPPRESSIONTANKS

90LTQUELLTANK

ENGINE

CATERPILLAR3412E

COMPRESSOROILCOOLER CHARGEAIRCOOLER

E/STOP

FIRESUPPRESSIONACTUACTOR

SULLAIR1150cfm/350psi

COMPRESSOR WIGGINSBOX

WATERTANKS

ENGINEAIRCLEANER

CRANE

AUTOMATICBREAKOUT WRENCH(HOBO)

FIRESUPPRESSION ACTUACTOR

E/STOP

TOOLBOX

EMERGENCYACCESS LADDER

THREADGREASER

CENTRALLUBE

HAMMEROIL

PUMPDRIVEBOX

DRIVELINE

I SOLATORBOX

BATTERYBOX

ENGINERADIATORHYD OILCOOLER/CHARGE AIRCOOLER

MUFFLER

EMERGENCYACCESS LADDER

E/STOP

FIRESUPPRESSION ACTUACTOR

COMPRESSORAIRCLEANER MASTACCESSLADDER

AIRRECEIVERTANK

BEANPUMP

Int-18 SKF Introduction

BI620404

General Locator (cont.)

WIGGINSBOX

WATERTANK

MASTACCESSLADDER

AIRRECEIVERTANK

LIGHT

4POTCAROUSEL

WINCH3629kg/f

MASTACCESSLADDER

MUFFLER

ROTARYDRIVE CAROUSEL

SAFETYLINE

BEANPUMP

WATERTANK

FIRESUPPRESSIONTANKS

90LTQUELLTANK

LIGHTS

WATERTANK

MASTVALVEASSEMBLY

WATERTANK E/STOP

FIRESUPPRESSIONACTUACTOR

COMPRESSORAIRCLEANER

BATTERYBOX

HAMMEROIL CENTRALLUBE

THREADGREASER

TILTSWITCH ISOLATORBOX

TOOLBOX

CRANE

DUSTSKIRT

FIRESUPPRESSION ACTUACTOR

E/STOP

SKF Introduction Int-19 General

REED R LL

Locator

4X35'

BI620404

Notes Int-20 SKF Introduction BI620404

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

BI620404

SKF Safety 1-3 Section 1 - Safety..............................................................................1-1 Section 1 Contents .........................................................................................................................1-3 Safety ...............................................................................................................................................1-5 Personal Protective Equipment ..................................................................................................1-5 Noise ..........................................................................................................................................1-5 Electrical Contact .......................................................................................................................1-5 Overhead and Buried Utilities.....................................................................................................1-5 Contact with Electric Wires .........................................................................................................1-6 Contaminated Air ........................................................................................................................1-6 Machine Stability ........................................................................................................................1-7 Moving and Rotating Parts .........................................................................................................1-8 High Pressure Air or Fluid ..........................................................................................................1-8 Before Operation ........................................................................................................................1-8 During Operation ........................................................................................................................1-9 Maintenance ..............................................................................................................................1-11 Safety Locator ..........................................................................................................................1-12 Notes ..............................................................................................................................................1-14 Section 1 Contents BI620404

BI620404

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

• plans and drilling assignment sheets.

Should be located, noted and emphasised on all drilling location

• 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.

Do not raise the mast or operate the drill rig within a minimum of

• 10 metres of any electrical power line or underground utility without a permit indicating 'danger zones' and minimum clearances.

SKF Safety 1-5 Safety

BI620404

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.

• Follow site emergency procedures. •

Do not attempt to leave the machine.

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.

1-6 SKF Safety Safety

BI620404

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