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.® April, 10 Version 1 Int-3 SKF 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 BI620403
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.® SKF Introduction Int-4 April, 10 Version 1
Safety Information
BI620403
Bucyrus International, Inc.® April, 10 Version 1 Int-5 SKF 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 ..............................................................................................................................................1-14 Section 2 - Operator's Cab / Controls ............................................. 2-1 Section 2 Contents .........................................................................................................................2-3 Graphic Symbol Legend ................................................................................................................2-5 Graphic Symbol Legend .............................................................................................................2-5 Warning Decals ...............................................................................................................................2-9 Warning Decals ..........................................................................................................................2-9 Operator Control and Instrument Panels ...................................................................................2-12 Control Panels ..........................................................................................................................2-12 Right Hand Control Panel.........................................................................................................2-12 Instrument Panel ......................................................................................................................2-14 Circuit Breakers ........................................................................................................................2-15 Light Switches ..........................................................................................................................2-15 System Pressure Gauge Panel ................................................................................................2-16 Left Hand Control Panels .........................................................................................................2-18 Cab Foot Controls ....................................................................................................................2-22 Thread Grease Switch..............................................................................................................2-22 Pipe Safety Arm Override Switch .............................................................................................2-22 Machine Stability ..........................................................................................................................2-23 Tramming Procedure ................................................................................................................2-23 Track Adjustments ....................................................................................................................2-23 New Machine Procedure ..........................................................................................................2-24 General Maintenance Checks While Tramming .......................................................................2-24 Roller Locations........................................................................................................................2-25 Temperature and Condition Record Chart for Walking .............................................................2-26 Propelling the Machine .............................................................................................................2-27 Stability Limits ..........................................................................................................................2-29 SKF Transient Stability Limits...................................................................................................2-30 Cab Heater .....................................................................................................................................2-31 Cab Heater Fault Isolation........................................................................................................2-31 Air Conditioner ..............................................................................................................................2-32 T7 Series Split System Air Conditioning Manual ......................................................................2-32 Section 1.0 Technical Data and Control Settings .....................................................................2-33 BI620403
Bucyrus International, Inc.® SKF Introduction Int-6 April, 10 Version 1 Contents Section 2.0 Installation and Commissioning.............................................................................2-35 Section 3.0 Routine Maintenance Procedures .........................................................................2-41 Section 4.0 Fault Diagnosis......................................................................................................2-42 Section 5.0 Reference Drawings ..............................................................................................2-51 Notes ..............................................................................................................................................2-56 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..........................................................................................3-14 Track Adjustments ....................................................................................................................3-14 New Machine Procedure ..........................................................................................................3-15 General Maintenance Checks While Tramming .......................................................................3-15 Roller Locations........................................................................................................................3-16 Temperature and Condition Record Chart for Walking .............................................................3-17 Metric Bolt Torque Specifications ...............................................................................................3-18 Metric Bolt Torque Specifications .............................................................................................3-18 Track Maintenance........................................................................................................................3-19 Before Operating the Machine .................................................................................................3-19 General Maintenance ...............................................................................................................3-19 Track Tension ................................................................................................................................3-20 Track Assembly ........................................................................................................................3-20 Hydraulic Tensioner ..................................................................................................................3-22 Track Tension Unit ....................................................................................................................3-23 Track and Support Rollers ...........................................................................................................3-24 Track Roller Assembly ..............................................................................................................3-24 Track Roller Unit .......................................................................................................................3-25 Track Roller – Removal and Disassembly................................................................................3-25 Track Roller – Assembly ...........................................................................................................3-26 Track Roller – Test and Install ..................................................................................................3-27 BI620403
Bucyrus International, Inc.® April, 10 Version 1 Int-7 SKF Introduction Contents Support Roller Assembly ..........................................................................................................3-29 Support Rollers Unit .................................................................................................................3-30 Support Roller – Removal and Disassembly ............................................................................3-30 Support Roller – Assembly .......................................................................................................3-31 Track Chain ...................................................................................................................................3-33 Track Chain – Separate............................................................................................................3-33 Track Chain Repair...................................................................................................................3-34 Track Shoes Installation...............................................................................................................3-36 Track Link Position ...................................................................................................................3-36 Track Shoe – Mounting to Track Chain ....................................................................................3-36 Track Shoe Bolt Torque (Direct Torque Method) .......................................................................3-38 Bolt Torque KN111 ....................................................................................................................3-38 Track Shoe Bolt Torque (Torque Turn Method) .........................................................................3-39 Bolt Torque KN111 ....................................................................................................................3-39 Track Chain and Shoe Installation ..............................................................................................3-40 Track Chain with Shoes............................................................................................................3-40 Track Chain and Shoe – Assembly and Installation .................................................................3-40 Final Drive Unit .............................................................................................................................3-42 Final Drive Unit .........................................................................................................................3-42 Removal from Track Frame ......................................................................................................3-43 Installation into Track Frame ....................................................................................................3-44 Final Drive Maintenance ...........................................................................................................3-45 Final Drive Oil ...........................................................................................................................3-46 F100 Final Drive Assembly .......................................................................................................3-48 Parking Brake – Description .....................................................................................................3-49 Final Drive – Disconnect and Parking Brake ............................................................................3-50 Towing Procedure – Gear Drive Disconnect ............................................................................3-50 Parking Brake – Description .....................................................................................................3-51 Parking Brake – Removal and Installation ...............................................................................3-51 General Description..................................................................................................................3-52 General Recommendations for Disassembly and Assembly Operations .................................3-52 Technical Features ...................................................................................................................3-54 Sealing Compounds and Adhesives.........................................................................................3-55 Filling and Checks ....................................................................................................................3-57 Service Schedule .....................................................................................................................3-57 Tightening Torques ...................................................................................................................3-58 Lubrication / Greasing – Grades and Application Range .........................................................3-58 General Checks ........................................................................................................................3-59 Disassembly and Assembly Operations ...................................................................................3-59 Troubleshooting ........................................................................................................................3-62 Special Tools ............................................................................................................................3-62 Idler Unit ........................................................................................................................................3-63 Idler Unit – Assembly................................................................................................................3-63 Idler Unit – Removal .................................................................................................................3-64 Track and Sprocket Inspection....................................................................................................3-67 Track Inspection and Wear Limit Guide ...................................................................................3-67 Sprocket Wear Patterns ...........................................................................................................3-72 BI620403
Bucyrus International, Inc.® SKF Introduction Int-8 April, 10 Version 1 Contents Auxiliary Crane .............................................................................................................................3-78 Hydraulic Crane – Rear Deck Crane Palfinger PC1500...........................................................3-78 Rear Deck Crane Palfinger PC1500 Service Information ........................................................3-79 Checking Bolted Connections ..................................................................................................3-79 Maintenance Chart ...................................................................................................................3-80 Lubrication ................................................................................................................................3-82 Hydraulic Fluids ........................................................................................................................3-85 Oil Change / Oil Maintenance ..................................................................................................3-86 Cleaning Agents and Equipment ..............................................................................................3-86 Repairing Paint Damage ..........................................................................................................3-87 Removal From Service and Disposal .......................................................................................3-87 Notes ..............................................................................................................................................3-88 Section 4 - Engine / Drive Train / Compressor ............................... 4-1 Section 4 Contents .........................................................................................................................4-3 Power Group Locator .....................................................................................................................4-5 Power Group Locator .................................................................................................................4-5 Test Point Locator ..........................................................................................................................4-6 Test Point Locator.......................................................................................................................4-6 Caterpillar Engine ...........................................................................................................................4-8 Caterpillar C27 Engine ...............................................................................................................4-8 Engine Mounts – Installation ......................................................................................................4-9 Engine and Compressor Air Cleaners ........................................................................................4-10 Engine and Compressor Air Cleaner Service Assembly ..........................................................4-10 Engine and Compressor Air Cleaner Service ............................................................................4-11 Flexible Drive Coupling ................................................................................................................4-14 Flexible Drive Coupling Service ...............................................................................................4-14 Pump Drive ....................................................................................................................................4-16 Pump Drive Assembly – Removal and Replacement ...............................................................4-16 Pump Drive Gearbox ................................................................................................................4-17 Pump Drive Gearbox Repair ....................................................................................................4-17 Hydraulic Pumps ..........................................................................................................................4-19 Hydraulic Pumps ......................................................................................................................4-19 Hydraulic Pumps – Removal and Replacement .......................................................................4-21 Compressor Installation ...............................................................................................................4-22 1700cfm / 125psi Compressor .................................................................................................4-22 Safety .......................................................................................................................................4-23 Compressor Installation............................................................................................................4-26 Compressor Drive Coupling .....................................................................................................4-27 Compressor Alignment .............................................................................................................4-28 Mounting Instructions for Arcusaflex™ Flywheel Couplings.....................................................4-29 Taper-Loc Bushing Installation – Model AC-T5.SN. F2. V1. 3535............................................4-30 Tightening Torques for Arcusaflex™ Flywheel Couplings ........................................................4-30 Compressor Shaft Seal ................................................................................................................4-31 Compressor Shaft Seal ............................................................................................................4-31 BI620403
Bucyrus International, Inc.® April, 10 Version 1 Int-9 SKF Introduction Contents Low Pressure Compressor ..........................................................................................................4-33 Description ...............................................................................................................................4-33 Compressed Air Functions .......................................................................................................4-33 Compressor Inlet Valve Control System ...................................................................................4-37 Inlet Valve .................................................................................................................................4-38 Compressor Regulation ............................................................................................................4-40 Relieving Regulators ................................................................................................................4-41 Reducing Regulators ................................................................................................................4-43 System Blowdown Valve ..........................................................................................................4-45 Running Blowdown Valve .........................................................................................................4-46 Running Blowdown Maintenance .............................................................................................4-47 Compressor Air and Oil Circuits – 1700cfm @ 125psi .............................................................4-48 Compressor Air Circuit Parts List .............................................................................................4-51 Compressor Air Circuit Legend ................................................................................................4-51 Compressor Control Set-up Closed Poppet Inlet – Shutdown .................................................4-52 Compressor Control Set-up Closed Poppet Inlet – Initial Start-up Below 50psi.......................4-53 Compressor Control Set-up Closed Poppet Inlet – Initial Start-up Above 50psi ......................4-54 Compressor Control Set-up Closed Poppet Inlet – Run Unloaded ..........................................4-55 Compressor Control Set-up Closed Poppet Inlet – Drilling ......................................................4-56 Compressor Control Set-up Closed Poppet Inlet – Shutting Down ..........................................4-57 Operation ..................................................................................................................................4-58 Compressor Maintenance ............................................................................................................4-60 General Maintenance ...............................................................................................................4-60 Discharge Check Valve ............................................................................................................4-62 Compressor Receiver Tank Assembly ......................................................................................4-63 Separator Elements..................................................................................................................4-64 Scavenge Line..........................................................................................................................4-65 Compressor Discharge Temperature Gauge, Switch and Sender ...........................................4-67 Minimum Pressure Valve ..........................................................................................................4-68 Minimum Pressure / Check Valve Maintenance .......................................................................4-68 Thermal Bypass Valve ..............................................................................................................4-69 Thermal Bypass Valve Maintenance ........................................................................................4-70 Compressor Fluid Filter ............................................................................................................4-72 Changing Filter Elements .........................................................................................................4-73 Oil Stop Valve ...........................................................................................................................4-74 Troubleshooting ........................................................................................................................4-75 Coolers ..........................................................................................................................................4-77 Hydraulic Oil / Hydraulic Cooler Assembly ...............................................................................4-77 Compressor Oil Cooler .............................................................................................................4-78 Fan Speed ................................................................................................................................4-78 Engine Cooler / Radiator ..........................................................................................................4-79 Aluminium Tube Air to Oil Cooler ...............................................................................................4-80 Aluminium Tube Air to Oil Cooler – Standard Parts .................................................................4-80 Removal Replacement .............................................................................................................4-81 Internal Cleaning ......................................................................................................................4-83 BI620403
Bucyrus International, Inc.® SKF Introduction Int-10 April, 10 Version 1 Contents Radiator Cooler .............................................................................................................................4-85 Typical Radiator Core – Standard Parts ...................................................................................4-85 Cleaning ...................................................................................................................................4-86 Tube Removal ..........................................................................................................................4-87 Seal Installation ........................................................................................................................4-88 Lubrication Seals and Tube Ends.............................................................................................4-88 Tube Installation .......................................................................................................................4-89 Notes ..............................................................................................................................................4-92 Section 5 - Dust Control System ..................................................... 5-1 Section 5 Contents .........................................................................................................................5-3 Dust Control System ......................................................................................................................5-5 Dust Control Systems .................................................................................................................5-5 Duraquip Dust Collector .............................................................................................................5-7 Dust Collector Assembly ..........................................................................................................5-10 Fan Wheel .................................................................................................................................5-11 Routine Maintenance ...............................................................................................................5-12 Water Injection ..............................................................................................................................5-13 Dust Collector and Water Injection Circuit ................................................................................5-13 Water Tanks..............................................................................................................................5-14 Water Injection Pump ...............................................................................................................5-15 Water Injection Relief Valve......................................................................................................5-15 Water Injection Control .............................................................................................................5-16 Water Injection Circuit ..............................................................................................................5-18 Water Pump ...................................................................................................................................5-19 Water Injection Pump Assembly ...............................................................................................5-19 Pump Specifications .................................................................................................................5-20 Torque Requirements ...............................................................................................................5-20 Servicing Instructions ...............................................................................................................5-20 Servicing the Plunger Packings................................................................................................5-20 Reassembling Plunger Packings..............................................................................................5-21 Servicing the Pump Valves .......................................................................................................5-21 Reassembling Valve Parts .......................................................................................................5-21 Servicing the Crankshaft ..........................................................................................................5-22 Servicing the Crossheads ........................................................................................................5-22 Replacing Piston Cup Seals .....................................................................................................5-23 Replacing Suction and Discharge Valves .................................................................................5-24 Replacing Power End Bearings................................................................................................5-25 Servicing the Wrist Pin Bearings ..............................................................................................5-26 Fastener Torque Requirements ................................................................................................5-26 Recommended Lubricants .......................................................................................................5-27 Water Pump Motor Repair ........................................................................................................5-27 Water Injection Hydraulic Control Valve Repair........................................................................5-27 Water Pump Drive Coupling .....................................................................................................5-27 Level and Flow Transducer ......................................................................................................5-27 Notes ..............................................................................................................................................5-28 BI620403
Bucyrus International, Inc.® April, 10 Version 1 Int-11 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 Mast Inspection ..........................................................................................................................6-6 Mast Assembly and Installation ....................................................................................................6-7 Mast Assembly ...........................................................................................................................6-7 Mast Pivot Caps .........................................................................................................................6-8 Mast Elevate Cylinders ...............................................................................................................6-9 Angle Drilling ..............................................................................................................................6-9 Mast / Drill Without Mast ..........................................................................................................6-10 Mast Assembly ..........................................................................................................................6-11 Raising the Mast ........................................................................................................................6-11 Hoist / Pulldown Cylinder.............................................................................................................6-13 Hoist / Pulldown Cylinder .........................................................................................................6-13 Feed Cylinder Service ..............................................................................................................6-14 Feed Cylinder Removal ............................................................................................................6-15 Installation ................................................................................................................................6-16 General Information..................................................................................................................6-17 Hoist / Pulldown Cable .................................................................................................................6-18 Hoist / Pulldown Cable Adjustment ..........................................................................................6-18 Hoist / Pulldown Cable Replacement .......................................................................................6-19 Wire Rope ................................................................................................................................6-20 Rotary Drive ..................................................................................................................................6-21 Alignment Procedure ................................................................................................................6-21 Rotary Drive Assembly .............................................................................................................6-22 Rotary Drive – Removal from Mast ..........................................................................................6-23 Rotary Drive – Installation ........................................................................................................6-23 Single Motor Rotary Drive Gearbox .........................................................................................6-24 Manufacturers Recommendations – Blast Hole Drilling Consumables ....................................6-25 Air Swivel ..................................................................................................................................6-26 Rotary Drive Motor – Repair .....................................................................................................6-27 Torque Limit Table Grade 8 UNC .............................................................................................6-28 Torque Limit Table Grade 8 UNF ..............................................................................................6-29 Rotary Drive Motor ...................................................................................................................6-30 Deck Wrench .................................................................................................................................6-31 Deck Wrench ............................................................................................................................6-31 H.O.B.O. Wrench ...........................................................................................................................6-32 H.O.B.O Wrench ......................................................................................................................6-32 Tong Dies .................................................................................................................................6-33 Optional Hydraulic Operated Bit Basket – H.O.B.B..................................................................6-34 Pipe Positioner ..............................................................................................................................6-35 Pipe Positioner .........................................................................................................................6-35 Carousel Pipe Rack ......................................................................................................................6-36 Carousel Pipe Rack..................................................................................................................6-36 BI620403
Bucyrus International, Inc.® SKF Introduction Int-12 April, 10 Version 1 Contents Chain Drive – Adjustment / Replace.........................................................................................6-36 Pipe Rack Bearings – Replace.................................................................................................6-37 Carousel Top Tube Bearing – Replace .....................................................................................6-38 Carousel Lower Bearing – Replace..........................................................................................6-40 Upper Pivot Support Bearing....................................................................................................6-41 Carousel Pivot Support Upper Bearing – Replace ...................................................................6-42 Pivot Support Pipe Lower Bushing ...........................................................................................6-43 Carousel Pivot Support Lower Bearing – Replace ...................................................................6-44 Mid Point Carousel Pivot Support ............................................................................................6-45 Top Sub Saver ...............................................................................................................................6-46 Replacement Procedure...........................................................................................................6-46 Notes ..............................................................................................................................................6-47 Section 7 - Hydraulic Systems ........................................................ 7-1 Section 7 Contents .........................................................................................................................7-3 Hydraulic Symbols .........................................................................................................................7-7 Hydraulic Symbols ......................................................................................................................7-7 Hydraulic Tank ................................................................................................................................7-9 Hydraulic Tank ............................................................................................................................7-9 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 Pump Arrangement ..................................................................................................................7-14 Right Track / Left Track / Rotation Pumps .................................................................................7-15 Technical Data ..........................................................................................................................7-15 Main Pump Adjustments...........................................................................................................7-16 Charge Pressure, High Pressure, P.O.R and Zero Position Settings .......................................7-17 Set Charge Pressure – 350psi (24bar).....................................................................................7-17 Linde HPR-02 Self-Regulating Pumps .....................................................................................7-18 Operational Parameters ...........................................................................................................7-20 Linde HPR-02 Pump Schematic...............................................................................................7-21 Controls ....................................................................................................................................7-22 Dimensions ...............................................................................................................................7-25 Charge Pumps .........................................................................................................................7-26 Hydraulic Piston Pumps – Removal and Replacement ............................................................7-27 Main Pumps .............................................................................................................................7-27 EP (24V DC) Control ................................................................................................................7-27 Setting Linde HPR-02 Main Pumps – Neutral Setting .............................................................7-28 Setting Linde HPR-02 Main Pumps – Pressure Settings .........................................................7-29 Setting Linde HPR-02 Main Pumps – Pre-setup Checks .........................................................7-30 Main Pumps Linde HPR-02 ......................................................................................................7-31 BI620403
Bucyrus International, Inc.® April, 10 Version 1 Int-13 SKF Introduction Contents Brake Test Procedure ...............................................................................................................7-32 Setting Procedure.....................................................................................................................7-32 Charge Circuit ...............................................................................................................................7-34 Charge Circuit Schematic .........................................................................................................7-34 Charge Circuit ..........................................................................................................................7-35 Routine Maintenance ...............................................................................................................7-36 Changing Filter Elements .........................................................................................................7-37 Main Pumps Circuit ......................................................................................................................7-38 Main Pumps Circuit ..................................................................................................................7-38 Loop Filters ...................................................................................................................................7-39 Loop Filters ...............................................................................................................................7-39 Routine Maintenance ...............................................................................................................7-39 Loop Filter Cross Section .........................................................................................................7-40 Filter Assembly Loop ................................................................................................................7-41 Changing Filter Elements .........................................................................................................7-42 Diverter Valve ................................................................................................................................7-43 Closed Loop Pump Circuit........................................................................................................7-43 Operation ..................................................................................................................................7-43 Diverter Valve ...........................................................................................................................7-43 Rotation Circuit .............................................................................................................................7-44 Basic Rotation Circuit ...............................................................................................................7-44 Rotation Circuit Schematic .......................................................................................................7-45 Rotation Circuit .........................................................................................................................7-46 Rotary Drive Gearbox Motor ........................................................................................................7-47 Variable Displacement Motor AA6M .........................................................................................7-47 Tram Circuit ...................................................................................................................................7-61 Tram Circuit ..............................................................................................................................7-61 Tram Circuit Schematic ............................................................................................................7-62 Pilot Control Manifold...................................................................................................................7-63 Pilot Control Manifold ...............................................................................................................7-63 Pilot Control Manifold Assembly ...............................................................................................7-64 Control Valve Assembly ............................................................................................................7-65 Electro Proportional Valves ......................................................................................................7-72 Proportional Valves Set-up .......................................................................................................7-73 Auto Pulldown Card..................................................................................................................7-73 Torque Control ..........................................................................................................................7-74 Proportional Pulldown ..............................................................................................................7-75 OEM Controllers / EP Levers ...................................................................................................7-76 Auxiliary Circuit ............................................................................................................................7-77 Auxiliary Circuit Functions ........................................................................................................7-77 Auxiliary Valves ........................................................................................................................7-79 Auxiliary Pump Circuit .................................................................................................................7-82 Feed and Auxiliary Pump Circuit ..............................................................................................7-82 Auxiliary Pump Circuit Schematic ............................................................................................7-83 Feed and Auxiliary Functions Pump .........................................................................................7-84 Pump Replacement – Start-up .................................................................................................7-84 BI620403
Bucyrus International, Inc.® SKF Introduction Int-14 April, 10 Version 1 Contents Jack Control and Mast Elevating Circuit ....................................................................................7-86 Jack Control and Mast Elevating Circuit Schematic .................................................................7-86 Jack Control and Mast Elevating Control Valve .......................................................................7-87 Jack Control and Mast Elevating Circuit...................................................................................7-88 Counterbalance Valves ................................................................................................................7-89 Counterbalance Valve Adjustments ..........................................................................................7-89 Internal Counterbalance Valve .................................................................................................7-90 Levelling Jack Cylinders ..............................................................................................................7-92 Jack Leg Cylinder .....................................................................................................................7-92 Counterbalance Valve Test Procedure .....................................................................................7-92 Mast Elevating Cylinders ..........................................................................................................7-93 Hydraulic Operated Breakout Wrench ........................................................................................7-94 H.O.B.O Wrench ......................................................................................................................7-94 Setting of H.O.B.O Sequence Valves .......................................................................................7-95 H.O B O Float Valve .................................................................................................................7-95 Hydraulic Feed Circuit ..................................................................................................................7-96 Hydraulic Feed Circuit ..............................................................................................................7-96 Hoist and Pulldown Control .........................................................................................................7-98 Directional Control Valve MP22 ................................................................................................7-98 Hoist / Pulldown Circuit Schematic .........................................................................................7-100 Feed Valve Assembly .................................................................................................................7-101 Feed Valve Assembly .............................................................................................................7-101 Control Valve Assembly .............................................................................................................7-103 Technical Data ........................................................................................................................7-103 Cooler Fan Circuit .......................................................................................................................7-105 Cooler Fan Circuit ..................................................................................................................7-105 Setting Cooler Fan Speed ......................................................................................................7-105 Hydraulic cooler – Thermal valve ...........................................................................................7-107 Basic Cooler Fan Circuit .........................................................................................................7-108 Cooler Fan Motor ........................................................................................................................7-109 Cooler Fan Motor Assembly ...................................................................................................7-109 Hydraulic Motor .......................................................................................................................7-110 Water Pump Motor .......................................................................................................................7-113 Water Pump Motor Repair Information ....................................................................................7-113 Shaft Seal Repair ....................................................................................................................7-114 Hydraulic Cylinder Repair ...........................................................................................................7-117 Hydraulic Cylinders .................................................................................................................7-117 General Information.................................................................................................................7-118 H Head ...................................................................................................................................7-120 N Head ...................................................................................................................................7-121 Z Head ....................................................................................................................................7-122 Z Head (Two Piece)................................................................................................................7-123 K Head ...................................................................................................................................7-124 M Head ...................................................................................................................................7-125 Z Piston ..................................................................................................................................7-126 Z Piston (Threaded) ...............................................................................................................7-127 BI620403
Bucyrus International, Inc.® April, 10 Version 1 Int-15 SKF Introduction Contents H and K Piston .......................................................................................................................7-128 M Piston .................................................................................................................................7-129 N Piston ..................................................................................................................................7-132 Notes ............................................................................................................................................7-133 Section 8 - Electrical components ................................................. 8-1 Section 8 Contents .........................................................................................................................8-3 Electrical Locator ............................................................................................................................8-5 Electrical Component Location...................................................................................................8-5 Jump Starting ..................................................................................................................................8-8 Jump Starting .............................................................................................................................8-8 Batteries ........................................................................................................................................8-10 Batteries ...................................................................................................................................8-10 Welding Precautions .....................................................................................................................8-11 Welding Precautions .................................................................................................................8-11 Electrical Components .................................................................................................................8-12 Electrical Circuits ......................................................................................................................8-12 Transducers..............................................................................................................................8-12 EP Levers .................................................................................................................................8-13 Joystick Adjustments ................................................................................................................8-14 Vigilante Guide ..............................................................................................................................8-16 Important Information ...............................................................................................................8-16 PLC ..........................................................................................................................................8-17 Touchscreen .............................................................................................................................8-20 Laser Depth System .................................................................................................................8-21 Distance Meter .........................................................................................................................8-24 Start Up and Shutdown ............................................................................................................8-24 Hydraulic Function Enable .......................................................................................................8-25 Alarms ......................................................................................................................................8-25 Solenoid Control .......................................................................................................................8-26 Auto Lube .................................................................................................................................8-29 Gauges .....................................................................................................................................8-29 Head Speed Module.................................................................................................................8-32 Engine Speed Card ..................................................................................................................8-33 Level Switches .........................................................................................................................8-33 Dust Suppression .....................................................................................................................8-33 Acknowledgements ..................................................................................................................8-34 Disclaimers ...............................................................................................................................8-34 Notes ..............................................................................................................................................8-35 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 BI620403
Bucyrus International, Inc.® SKF Introduction Int-16 April, 10 Version 1 Contents Central Lube Tank Assembly ......................................................................................................9-6 Auto Lube Grease Pump ............................................................................................................9-7 Auto Lube Tube Pump..............................................................................................................9-13 Graco Vent Valve ......................................................................................................................9-18 Central Lube System Circuit.....................................................................................................9-19 Basic Operational Principles of Auto Lube Injectors.................................................................9-20 SL-V and SL-V XL Injectors......................................................................................................9-20 SL-1 and Sl-11 Injectors ...........................................................................................................9-21 SL-32 Injectors .........................................................................................................................9-22 Typical Grease System Circuit .................................................................................................9-23 First 50 Hours Service ..............................................................................................................9-24 Lube Faults / Operation ............................................................................................................9-25 Auto Lube Timer .......................................................................................................................9-26 Lube Pressure Screen..............................................................................................................9-26 Air Service Units ...........................................................................................................................9-27 Filter Regulator .........................................................................................................................9-27 Air Line Oiler .............................................................................................................................9-28 Soft Start Dump Valve ..............................................................................................................9-29 Air Service Unit .........................................................................................................................9-30 Pipe Thread Lubricator ................................................................................................................9-31 Air Operator Pipe Thread Pump ...............................................................................................9-31 Filter Locator .................................................................................................................................9-39 Filter Locator Assembly ............................................................................................................9-39 Lubrication and Preventive Maintenance ...................................................................................9-40 General Lubrication ..................................................................................................................9-40 Equipment Lubrication..............................................................................................................9-40 Care of Lubrication Points ........................................................................................................9-40 Safety .......................................................................................................................................9-41 Track Gear................................................................................................................................9-42 Engine Maintenance.................................................................................................................9-43 Air Cleaners ..............................................................................................................................9-44 Air Filter Elements ....................................................................................................................9-44 Alternator Maintenance ............................................................................................................9-44 Pump Drive and Drive Shaft Maintenance ...............................................................................9-45 Compressor Maintenance ........................................................................................................9-45 Cooler Packs ............................................................................................................................9-45 A-frame and Pivot Point Maintenance ......................................................................................9-47 Pull Down and Hoist Ropes and Sheaves Maintenance ..........................................................9-47 Rotary Head Maintenance........................................................................................................9-47 Hydraulic System Maintenance ................................................................................................9-49 Hydraulic Maintenance .............................................................................................................9-49 Water Pump Maintenance ........................................................................................................9-49 Cab Maintenance .....................................................................................................................9-49 Air Conditioner Maintenance ....................................................................................................9-51 Battery Maintenance ................................................................................................................9-51 Lubrication System Maintenance .............................................................................................9-51 BI620403
Bucyrus International, Inc.® April, 10 Version 1 Int-17 SKF Introduction Contents Fire Suppression Maintenance.................................................................................................9-51 Drill Folding Stairway – Inspection Requirements ....................................................................9-53 Weld Inspection Schedule ...........................................................................................................9-54 Weld Inspection Schedule SK Series .......................................................................................9-54 Track and Sprocket Inspection....................................................................................................9-55 Track Inspection and Wear Limit Guide ...................................................................................9-55 Sprocket Wear Patterns ...........................................................................................................9-60 Lubrication Recommendations ...................................................................................................9-66 Lubrication Recommendations .................................................................................................9-66 Lubrication and Maintenance Chart – 250hr ..............................................................................9-67 Lubrication and Maintenance Chart – 500hr ..............................................................................9-77 Lubrication and Maintenance Chart – 1000hr ............................................................................9-88 Lubrication and Maintenance Chart – 2000hr ............................................................................9-99 Lubricant Specifications .............................................................................................................9-111 Hydraulic System ....................................................................................................................9-111 Hydraulic Tank Capacity ..........................................................................................................9-111 Compressor Lubrication ..........................................................................................................9-112 Compressor Lubricant Specifications ......................................................................................9-112 Lubricating Grease ..................................................................................................................9-113 Gear Lubricant.........................................................................................................................9-113 Scheduled Oil Sampling Analysis ............................................................................................9-113 Torque Values for Split Flange Connections ............................................................................9-114 Torque Values for Split Flange Connections ...........................................................................9-114 Procedure No. 1-87 Revision A ...............................................................................................9-116 Notes .............................................................................................................................................9-117 BI620403
Bucyrus International, Inc.® SKF Introduction Int-18 April, 10 Version 1
General Locator Compressor Air Cleaner Hydraulic Tank Mast Raise Cylinder B6 Inter-trac Pneumatic Stairs Box Sliding Viewing Hatch Dust Skirt Pneumatic Stairs Cotton Reel Pulldown Rope Hoist Rope Rotary Drive Drill Pipe Travelling Sheaves Dust Collector Mast Access Ladder Safety Line Top Sheave Pneumatic Stairs Compressor Air Cleaner Laser NO PARKING WITHIN 50 4 Pot Carousel 4 X 35' Battery Box Isolator Box Air Conditioner Pressuriser Transducer Box Main J-box 1800 Wiggins Box Tool Box BI620403
General Locator
Bucyrus International, Inc.® April, 10 Version 1 Int-19 SKF Introduction General Locator General Locator
Compressor Air Cleaner Inter-trac Pneumatic Stairs Compressor Air Cleaner Engine Radiator Wiggins Box Mast Access Ladder Fire Suppression Tanks Dust Collector Tilt Switch Drill Pipe Thread Greaser Drill Bit Bit Sub Dust Skirt Bean Pump Wash Down Pump 1800 Wiggins Box 15877 BI620403
(cont.)
General Locator (cont.)
Bucyrus International, Inc.® SKF Introduction Int-20 April, 10 Version 1
General Locator
Engine Cooler Hydraulic Tank Engine & Compressor Air Cleaners Transducer Box Main Electrical J Box Dust Collector Mast Access Ladder Fire Suppression Under Tool Box Oil Reserve Tank Central Lube Tank Palfinger Crane Cotton Reel Muffler Muffler Fire Suppression Yanmar Wash Down Pump BI620403
Bucyrus International, Inc.® April, 10 Version 1 Int-21 SKF Introduction Notes BI620403
Bucyrus International, Inc.® SKF Introduction Int-22 April, 10 Version 1 Notes BI620403
Section 1 Safety
Bucyrus International, Inc.®
Safety April, 10 Version 1 1-1 SKF Safety BI620403
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).
Bucyrus International, Inc.®
BI620403
Bucyrus International, Inc.® April, 10 Version 1 1-3 SKF Safety 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 ..............................................................................................................................................1-14 BI620403
BI620403
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 Bucyrus 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
Should be located, noted and emphasised on all drilling
• location plans and drilling assignment sheets. Whenever overhead power lines exist on or near a drilling site or • project, consider all wires to be live and dangerous. Watch for sagging power lines before entering a site. Do not lift
• power lines to gain entrance.
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.
Bucyrus International, Inc.® April, 10 Version 1 1-5 SKF Safety Safety
BI620403
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