CAT Bucyrus TEREX Reedrill Infinity Blasthole Drill Series SKF-12 Service Manual – PDF DOWNLOAD by www.heydownloads.com

Technical Manual

BI620153

BUCYRUS

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Service Manual Serial No. 1D68E74 Inﬁnity Blasthole Drill Series SKF-12 BI620153

Parts Ordering and Product Support

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 unauthorized 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 Terex Reedrill's furnished manuals, or other written instructions, or which are operated with other than genuine Terex Reedrill parts.

Your cooperation 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 Terex Reedrill Model Number and Serial Number when ordering parts. This information is found on the machine nameplate. Rock Drills have the serial number stamped on the cylinder.

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 motor freight collect or UPS prepaid and charged on our invoice. Shipments cannot be made on open account until your credit has been approved by our Accounting Department.

Introduction i

MAILING ADDRESS FOR PARTS ORDER ENTRY SHIPPING ADDRESS Terex Reedrill QLD Terex Reedrill QLD Terex Reedrill QLD P. O. Box 5729 Telephone (07) 4952 5600 10-12 Corporate Dve Mackay QLD, 4741 Fax (07) 4952 5311 Mackay QLD, 4741 Australian Branches Kelmscott Brisbane Newcastle Lot 21 Bryant Rd 585 Curtain Ave East 139 Racecourse Rd Kelscott WA 6111 Ea gle Farm QLD 4009 Rutherford NSW 2320 Ph. (08) 9495 7700 Ph. (07) 3632 4600 Ph. (02) 4932 0000 Fax (08) 9495 7750 Fax. (07) 3216 3934 Fax (02) 4932 0733 © TEREX REEDRILL 2006 BI620153

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

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 recognized 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 : _________________________________________

ii Introduction

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Product Description

WARNING: DO NOT use this machine for any other purpose than blasthole drilling. The SKF series rotary blasthole drill is designed for blasthole drilling purposes only.

Any other use could result in personal injury, property damage and will void the warranty.

The Terex Reedrill Inﬁnity Series is speciﬁcally designed for Blast Hole Drilling Operations.

The Inﬁnity Series SKF-12 is a crawler mounted drill rig, which consist of two (2) major assemblies:

1. Rotary Drill Assembly

2. Excavator Type Undercarriage

The Rotary Drill assembly is made up of the Engine Package, Compressor Package, Hydraulic System, Rotary Drive, Pull-Down and Hoisting System and Drill Pipe Handling mechanism.

The Crawlers are powered by two (2) hydrostatic motors. Each Crawler has its own independent, variable and reversible speed control, and is equipped with triple cleated grousers.

Manual Contents

This manual is furnished with your Terex Reedrill Inﬁnity Series Blasthole Drill to aid you in performing the necessary service work to maintain your blasthole drill in good running condition.

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 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 Terex Reedrill.

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.

Introduction iii

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SKF-12 Component Locator

COTT ONREEL

CRANE CONTROLS

O PE RATORS CABIN

A/C PRESS URISER

CABAIRCONDITIONER

FIRESUPPRESS ION ACTUACT OR

E /STOP

T RANSDUCERBOX

MAIN ELECTRICALCABINET

HYD T ANK

MAS TRAISECYLINDER

FIRESUPPRESSIONTANKS

90LTQUELLT ANK

ENG INE

CATERPILLAR 3412E

COMPRESSOROILCOOLER CHARGEAIRCOOLER

E/STOP

FIRESUPPRESSIONACTUACTOR

COMPRESSOR

SULL AI R1150 cfm/350psi

WIGGINSBOX

WATERTANKS

E NGINE AIRCLEANER

ROTARY DRIVE

CRANE

AUT OMATIC BREAKOUT WRENCH (HOBO)

FIRE SUPP RE SS IO NACTUACTOR

E/STOP

T OOLBOX

EMERGENCY ACCESS

LADDER

T HREADGREASER

CENTRALLUBE

HAMMEROIL

P UMPDRIV EBOX

DRIV E LINE

ISOLATORBOX

BATTE RY BOX

ENG INERADIATORHYD

O ILCOOLE R/ CHARGE AIRCO OLER

MUF FL ER

E MERGENCY ACCESS LADDER

E /STOP

F IRE SUPP RESS ION ACTUACTOR

COMPRESSO R AIRCLEANER

MAST ACCESS LADDER

AIR RECEIVE RTANK

BEANPUMP

iv Introduction

Fig. i-1 SKF-12 Top View

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Introduction v

TER EX REEDRILL MAS T ACCE SS L ADDER DUS T SKIRT ISO LATO RBOX BATTE RY BOX 90LT Q UE LLT ANK S AFE TY LINE F IRESUPPRESS ION TANKS MAST ACCESS LADDER LIGHT LIGHTS E/STOP FIRE SUPPRESSION ACTUATOR E/STOP F IRE SUPP RESS ION ACT UACT OR BI620153

SKF-12 Component Locator

vi Introduction

Contents Introduction Ordering Information / Product Support ...................................................................................i Safety Information ......................................................................................................................ii Product Description ..................................................................................................................iii Component Locator ..................................................................................................................iv Section 1 Safety Overview of Potential Hazards ...............................................................................................1-2 Safety .......................................................................................................................................1-2 Personal Protective Equipment ..........................................................................................................1-2 Noise ..................................................................................................................................................1-2 Electrical Contact ...............................................................................................................................1-2 Overhead and Buried Utilities ............................................................................................................1-2 Clearance from High Voltage Lines ....................................................................................................1-3 Machine Stability ................................................................................................................................1-4 Moving and Rotating Parts .................................................................................................................1-5 High Pressure Air or Fluid ..................................................................................................................1-5 Before Operation ................................................................................................................................1-5 During Operation ................................................................................................................................1-6 Maintenance .......................................................................................................................................1-8 General Locator .................................................................................................................................1-9 Section 2 Operator's cab / Controls Graphic Symbol Legend .........................................................................................................2-2 Warning Decals .......................................................................................................................2-6 Operator Control Panel ...........................................................................................................2-8 System Pressure Gauge Panel ............................................................................................2-11 Switch Panel ..........................................................................................................................2-12 Switches/Diagnostic Control Panel .....................................................................................2-15 Cab Heater Fault Isolation ....................................................................................................2-16 AC/Heater/Pressurizer Unit ..................................................................................................2-17 Air Conditioner .....................................................................................................................2-18 Section 3 Mainframe / Crawlers Leveling Jacks .........................................................................................................................3-2 Remove ..............................................................................................................................................3-3 Repair .................................................................................................................................................3-3 Replace ..............................................................................................................................................3-3 Lubricating Jack Casings ...................................................................................................................3-3 Mast Elevating Cylinders ........................................................................................................3-4 Remove ..............................................................................................................................................3-5 BI620153

Table of

Table BI620153

of Contents

Introduction vii

Section 3 Mainframe / Crawlers Repair .................................................................................................................................................3-5 Replace ..............................................................................................................................................3-5 Crawler Assembly ...................................................................................................................3-6 Crawler Component Repair ................................................................................................................3-7 Crawler Serial Number Location ............................................................................................3-7 Metric Bolt Torque Speciﬁcations .........................................................................................3-8 Track Maintenance ..................................................................................................................3-9 Before Operating the Machine ...........................................................................................................3-9 General Maintenance .........................................................................................................................3-9 Track Tension Adjustment ....................................................................................................3-10 Track Chain ............................................................................................................................3-12 Separate ...........................................................................................................................................3-12 Track Link Repair & Replace............................................................................................................3-14 Track Shoes ...........................................................................................................................3-16 Mounting to Track Chain ..................................................................................................................3-16 Track Shoe Bolt Torque (Direct Torque Method) ..............................................................................3-17 Track Shoe Bolt Torque (Torque Turn Method) ................................................................................3-17 Track Assembly .....................................................................................................................3-20 Track Chain & Shoe - Assembly & Installation .................................................................................3-20 Final Drive ..............................................................................................................................3-22 General Description .........................................................................................................................3-22 Removal from Track Frame ..............................................................................................................3-23 Installation into Track Frame ............................................................................................................3-24 Oil Check/Change ............................................................................................................................3-25 Oil Speciﬁcations ..............................................................................................................................3-26 Recommended Oils ..........................................................................................................................3-26 Temperature Range Chart ................................................................................................................3-27 Final Drive Assembly ............................................................................................................3-28 Parking Brake - Description .............................................................................................................3-30 Parking Brake - Removal & Installation ............................................................................................3-31 Towing Procedure ............................................................................................................................3-31 Final Drive Assembly Manual ...............................................................................................3-33 Idler Unit .................................................................................................................................3-90 General Description .........................................................................................................................3-90 Idler Assembly ..................................................................................................................................3-91 Removal & Disassembly ..................................................................................................................3-92 Assembly & Installation ....................................................................................................................3-94 Track Tension Unit ................................................................................................................3-96 Installation ........................................................................................................................................3-97 Track Rollers ..........................................................................................................................3-98 General Description .........................................................................................................................3-98 Track Roller Assembly......................................................................................................................3-99 Removal & Disassembly ................................................................................................................3-100 Assembly ........................................................................................................................................3-101 Test & Install ...................................................................................................................................3-102

Section 3 Mainframe / Crawlers

viii Introduction

Engine Service Procedures ....................................................................................................4-3 Power Train ........................................................................................................................................4-3 Caterpillar 3412E Engine ...................................................................................................................4-4 Engine and Compressor Air Cleaner Service .....................................................................................4-5 Flexible Drive Coupling ..........................................................................................................4-6 Pump Drive ............................................................................................................................4-10 Pump Drive Assembly - Removal and Replacement .......................................................................4-10 Pump Drive Gearbox - Repair ..........................................................................................................4-12 Hydraulic Pumps ...................................................................................................................4-13 Compressor Service Procedures ........................................................................................4-15 Compressor Drive Coupling - Removal and Replacement ..............................................................4-16 Mounting Instructions for Arcusaﬂex Flywheel Couplings ................................................................4-18 Taper-Loc Bushing Installation .........................................................................................................4-18 Before Installation and Start-Up of New or Rebuilt Compressor ......................................................4-19 Compressor Unit - Installation ..........................................................................................................4-19 High Pressure Compressor ..................................................................................................4-20 Safety ...............................................................................................................................................4-20 Description .......................................................................................................................................4-23 Compressed Air Functions ...............................................................................................................4-23 Compressor Fluid Circuit .....................................................................................................4-27 Compressor Condensation Table ........................................................................................4-29 Compressor Functional Description ...................................................................................4-30 Compressor Operation .........................................................................................................4-33 Compressor Air Circuit ....................................................................................................................4-38 Initial Start-up Procedure .................................................................................................................4-39 Regulator Set-up ..............................................................................................................................4-39 Subsequent Start-up Procedure .......................................................................................................4-40 Shutdown Procedure ........................................................................................................................4-40 General Operating Instructions ........................................................................................................4-40 General Maintenance ............................................................................................................4-40 Daily Operation ................................................................................................................................4-41 50, 250, 500, & 1000 Hours .............................................................................................................4-41 Compressor Maintenance ....................................................................................................4-42 Main Drive Shaft Seal Replacement ................................................................................................4-42 Interstage Tube ................................................................................................................................4-44 Discharge Check Valve ....................................................................................................................4-45 Support Rollers ...................................................................................................................3-103 General Description .......................................................................................................................3-103 Support Roller Assembly ................................................................................................................3-104 Removal & Disassembly ................................................................................................................3-105 Assembly ........................................................................................................................................3-106

Table of Contents Section 4 Engine / Drive train / Compressor

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Section 4 Engine / Drive train / Compressor

Section 5 Dust Control Systems

Section 6 Mast / Rotary drive / Pipe rack

Introduction ix Table of Contents

Dust Control System Functions ............................................................................................5-2 Basic Water Injection Circuit ..............................................................................................................5-2 Water Injection Circuit ............................................................................................................5-3 Dust Collector/Water Injection Pressure Adjustment ..........................................................5-5 Water Pump Assembly............................................................................................................5-6 Water Pump Service Manual..............................................................................................................5-7 Water Pump Motor Service Manual .................................................................................................5-32

12 Meter Mast Assembly .........................................................................................................6-2 Cable Tensioning Assembly ...................................................................................................6-3 Feed Cylinder - Removal and Installation .............................................................................6-4 SKF-12 Feed Cylinder .............................................................................................................6-6 Cylinder Repair ..................................................................................................................................6-7 Hoist / Pulldown Cable Adjustment .......................................................................................6-8 Auto Tensioning (optional) - Operating Principle ..............................................................................6-11 Auto Tensioning - Cable Installation & Adjustment ...........................................................................6-14 Hoist / Pulldown Cable Replacement ..................................................................................6-16 Rotary Head Guide Alignment ............................................................................................6-17 Separator/Receiver Tank ..................................................................................................................4-46 Minimum Pressure Check Valve ......................................................................................................4-47 Scavenge Line .................................................................................................................................4-48 Compressor Discharge Temperature Switches, Senders, & Gauges ..............................................4-49 Thermal Bypass Valve......................................................................................................................4-51 Compressor Fluid Filter ....................................................................................................................4-54 Fluid Stop Valve ...............................................................................................................................4-56 Inlet Valve .........................................................................................................................................4-58 Relieving Regulators ........................................................................................................................4-59 Reducing Regulators ........................................................................................................................4-61 System Blowdown Valve ..................................................................................................................4-63 Running Blowdown Valve .................................................................................................................4-64 Moisture Separator ...........................................................................................................................4-66 Troubleshooting................................................................................................................................4-66 Recommended Spare Parts Listing .................................................................................................4-68 Fan/Oil Cooler Piping ............................................................................................................4-69 Fan Motor and Fan Installation ............................................................................................4-70 Radiator/Oil Cooler Repair ...................................................................................................4-72 Mesabi Radiator & Cores Service Manual .......................................................................................4-73 High Pressure Compressor Fluid Cooler ............................................................................4-81

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Section 6 Mast / Rotary drive / Pipe rack

Section 7 Hydraulic systems

x Introduction Rotary Drive Assembly ........................................................................................................6-19 Removal from Mast ..........................................................................................................................6-20 Installation .............................................................................................................................6-20 Rotary Drive Gearbox ...........................................................................................................6-21 Rotary Drive Assembly and Parts List ..............................................................................................6-21 Rotary Drive Gearbox - Repair Manual ............................................................................................6-23 Air Swivel .........................................................................................................................................6-63 Rotary Drive Motor - Repair .............................................................................................................6-26 Winch Assembly ....................................................................................................................6-66 Precautions on the Use of Winches .................................................................................................6-66 Wire Rope ........................................................................................................................................6-66 Wedge Sockets ................................................................................................................................6-68 Grooved Drums ................................................................................................................................6-69 Plain (Smooth) Drums ......................................................................................................................6-69 Drums - Multiple Layers ...................................................................................................................6-71 Winch Service Manual - Model BG8A ..............................................................................................6-73 Deck Wrench........................................................................................................................6-104 H.O.B.O. Wrench .................................................................................................................6-105 Tong Dies .......................................................................................................................................6-106 Pipe Positioner ....................................................................................................................6-107 Carousel Pipe Rack .............................................................................................................6-108 Chain Drive - Adjust/Replace .........................................................................................................6-108 Pipe Rack Bearings - Replace .......................................................................................................6-109 Carousel Top Tube Bearing - Replace ...........................................................................................6-110 Carousel Lower Bearing - Replace ................................................................................................6-113 Carousel Pivot Support Upper Bearing - Replace ..........................................................................6-115 Carousel Pivot Support Lower Bearing - Replace ..........................................................................6-117 Carousel Pivot Support Mid-Point Bearing - Replace ....................................................................6-118

Hydraulic Symbols ..................................................................................................................7-2 Hydraulic Tank .........................................................................................................................7-4 Hydraulic System ....................................................................................................................7-5 Pressure Setting Sequence ...............................................................................................................7-6 Main Return and Case Drain Filters ......................................................................................7-7 Routine Maintenance .........................................................................................................................7-8 Changing Filter Elements ...................................................................................................................7-8 Main Hydraulic Pumps ............................................................................................................7-9 Hydraulic Pump - Identiﬁcation ..........................................................................................................7-9 Hydraulic Piston Pumps - Removal and Replacement ....................................................................7-10 Right Track/Pulldown, Left Track/Rotation Pumps ..............................................................7-6 Technical Data ..................................................................................................................................7-11 AA4VG 125 Hydraulic Pump EP2 Control .......................................................................................7-13

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Section 7 Hydraulic systems

Introduction xi Table of Contents

AA4VG EP Contoller ........................................................................................................................7-14 EP (24VDC) Control .........................................................................................................................7-15 Adjustment of Drill and Tram Controllers .........................................................................................7-16 Start-Up Procedure ..........................................................................................................................7-17 Connections .....................................................................................................................................7-19 Before Making Pump Adjustments ...................................................................................................7-20 Mechanical Zero Position Adjustment ..............................................................................................7-21 Hydraulic Centering Adjustment .......................................................................................................7-22 Set Charge Pressure ........................................................................................................................7-24 Set Pressure Override (P.O.R.) ........................................................................................................7-24 Set Crossover Relief (High Pressure) ..............................................................................................7-26 Removal and Installation ..................................................................................................................7-27 Hydraulic Piston Pumps - Maintenance ..............................................................................7-28 Hydraulic Piston Pump - Trouble Shooting ........................................................................7-30 Charge Circuit .......................................................................................................................7-34 Charge Circuit Gear Pump ...............................................................................................................7-34 Routine Maintenance .......................................................................................................................7-37 Changing Filter Elements .................................................................................................................7-37 Loop Filters ............................................................................................................................7-38 Routine Maintenance .......................................................................................................................7-41 Changing Filter Elements .................................................................................................................7-41 Diverter Valve ........................................................................................................................7-42 Operation .........................................................................................................................................7-42 Hydraulic Feed and Rotation Circuits .................................................................................7-43 Basic Rotation Circuit .......................................................................................................................7-43 Rotation Circuit .................................................................................................................................7-44 Basic Pulldown Circuit ......................................................................................................................7-45 Hoist / Pulldown Circuit ....................................................................................................................7-46 Drill / Tram Control Circuit ...................................................................................................7-47 Operation .........................................................................................................................................7-47 Drill / Tram Circuit .............................................................................................................................7-49 Rope Tensioning Circuit .......................................................................................................7-50 Rotary Drive Gearbox Motor ................................................................................................7-51 Technical Data ..................................................................................................................................7-52 Shaft Seal Replacement ..................................................................................................................7-58 Installation ........................................................................................................................................7-59 Start-Up Procedure ..........................................................................................................................7-60 Troubleshooting Procedure ..............................................................................................................7-61 Routine Maintenance .......................................................................................................................7-64 Port Information ................................................................................................................................7-65 Fan and Auxiliary Pump Circuit ...........................................................................................7-65 Fan and Auxiliary Functions Pump ...................................................................................................7-67 Function of Load Sensing Control ....................................................................................................7-67 Standby Pressure .............................................................................................................................7-67 BI620153

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

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Section 7 Hydraulic systems

Section 8 Electrical Components

xii Introduction Main Pressure ..................................................................................................................................7-67 Hydraulic Pumps ...................................................................................................................7-68 Hydraulic Piston Pumps - Removal and Replacement ....................................................................7-68 Model AA11VLO Hydraulic Piston Pumps - Repair ..........................................................................7-68 New or Rebuilt Hydraulic Pumps - Start-Up .......................................................................7-70 Start-Up Procedure ..........................................................................................................................7-70 Auxiliary Functions / Fan Circuit .........................................................................................7-72 Operation .........................................................................................................................................7-73 Auxiliary Priority Function .................................................................................................................7-78 Cooler Fan Circuit .................................................................................................................7-79 Hydraulic Cooler - Thermal Valve.....................................................................................................7-80 Cooler Fan Motor ..................................................................................................................7-81 Jack and Mast Elevate Circuit ..............................................................................................7-88 Counterbalance Valve Adjustment ...................................................................................................7-90 Mast Elevating Cylinders Counterbalance Valves .............................................................7-91 Leveling Jack Cylinders .......................................................................................................7-92 Jack Counterbalance Valve Adjustment ...........................................................................................7-92 Auxiliary Functions/6 Spool Valve .......................................................................................7-93 3 Bank Valve ....................................................................................................................................7-94 6 Bank Valve ....................................................................................................................................7-94 9 Bank Valve ....................................................................................................................................7-94 Hydraulic Operated Breakout Wrench (HOBO) ................................................................. 7-96 Setting of Sequence Valves .............................................................................................................7-96 Carousel Rotate Motor ..........................................................................................................7-97 Pilot Control Manifold .........................................................................................................7-104 Pilot Control Manifold Schematic ...................................................................................................7-105 Hydraulic Gear Pumps ........................................................................................................7-119 Hydraulic Gear Pumps - Removal and Replacement ....................................................................7-119 Hydraulic Gear Pumps - Shaft Seal Removal and Replacement ...................................................7-120 Dust Collector / Water Injection Circuit .............................................................................7-122 Pressure Adjustment ......................................................................................................................7-122 Hydraulic Cylinder Repair ..................................................................................................7-124

Electrical Symbols ..................................................................................................................8-2 Welding Precautions ...............................................................................................................8-3 Electrical Components ...........................................................................................................8-4 Electrical Locator ................................................................................................................................8-5 Machine Isolation ...............................................................................................................................8-5 Batteries and Alternator ......................................................................................................................8-6 Batteries .............................................................................................................................................8-6 Jump Starting .....................................................................................................................................8-7 Electrical Circuits ................................................................................................................................8-8

Table of Contents

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Section 8 Electrical Components

Section 9 Lubrication and Preventive Maintenance

Introduction xiii Transducers .......................................................................................................................................8-8 Joystick Adjustments ..........................................................................................................................8-9 Vigilante Drill Management System .................................................................................................8-12 Drill Mode Screen .............................................................................................................................8-12 Laser Depth System .........................................................................................................................8-13 Vigilante System Screens ................................................................................................................8-15 Drill Electrical Guide .........................................................................................................................8-19 Ladder Proximity Switch ...................................................................................................................8-35 Jacks Proximity Switch .....................................................................................................................8-35 LDM 40 A Laser ................................................................................................................................8-36 Radiator Level Switch ......................................................................................................................8-48 Hammer Oil Level Transducer .........................................................................................................8-52 Combined Pressure Sensor .............................................................................................................8-54 Access Light Timer ...........................................................................................................................8-63 Rod Counter Proximity Switch .........................................................................................................8-64 Engine Flash Codes 3412E .............................................................................................................8-65 Caterpillar 3412E Electrical System .................................................................................................8-67

Service Points - SKF-12 ..........................................................................................................9-2 Lubrication and Preventative Maintenance ..........................................................................9-4 Safety Precautions .............................................................................................................................9-4 Isolation - Battery Switch ....................................................................................................................9-5 Track Checks and Lubrication ............................................................................................................9-5 Engine Checks and Servicing ............................................................................................................9-6 Alternator Checks and Servicing ........................................................................................................9-7 Air Conditioner Checks and Servicing ................................................................................................9-8 Drive Shaft Checks and Maintenance ................................................................................................9-8 Compressor Checks and Servicing ....................................................................................................9-9 Cooler Checks and Servicing ...........................................................................................................9-10 Hydraulic Checks and Servicing ......................................................................................................9-11 A-Frame and Mast Pivot Point Checks and Maintenance ................................................................9-12 Rotary Head Check and Service Points ...........................................................................................9-13 Checks and Servicing Pull Down/Hoist Sheaves and Maintenance ................................................9-14 Cabin Checks and Service Points ....................................................................................................9-15 Fire Suppression Checks and Servicing ..........................................................................................9-15 Battery Checks and Servicing ..........................................................................................................9-16 Bean Pump Checks and Miantenance .............................................................................................9-16 Lubrication System Checks and Servicing ........................................................................9-17 Lubrication and Maintenance Chart - 250, 750, 1250, 1750 Hrs ........................................9-18 Lubrication and Maintenance Chart - 500, 1500 Hrs ..........................................................9-27 Lubrication and Maintenance Chart - 1000 Hrs ..................................................................9-36 Lubrication and Maintenance Chart - 2000 Hrs ..................................................................9-45 Lubrication - General, Compressor and Winch .................................................................9-56

Table of Contents BI620153

Section 9 Lubrication and Preventive Maintenance

Section 10 Optional Equipment

xiv Introduction Lubricant Speciﬁcations ......................................................................................................9-57 Compressor ......................................................................................................................................9-57 Lubricating Grease ...........................................................................................................................9-57 Gear Lubricant .................................................................................................................................9-57 Hydraulic System .............................................................................................................................9-58 Hydraulic Tank Capacity ...................................................................................................................9-58 Preventative Maintenance ....................................................................................................9-59 Hydraulic System Maintenance ........................................................................................................9-59 Cooling System Maintenance ..........................................................................................................9-59 Torque Values for Standard Fasteners................................................................................9-62 Torque Values for Split Flange Connections ......................................................................9-63 Torque Values for Hydraulic Tubes and Fittings ................................................................9-64

Auxiliary Crane ......................................................................................................................10-2 Palﬁnger Hydraulic Crane ................................................................................................................10-2 Remote Winch Control........................................................................................................10-33 Auto Lube System ...............................................................................................................10-34 Description .....................................................................................................................................10-34 Lube Pump Air Motor ..........................................................................................................10-35 Parts List ........................................................................................................................................10-37 Service and Disassembly ...............................................................................................................10-38 Troubleshooting..............................................................................................................................10-39 Lube Pump Tube .................................................................................................................10-40 Service and Operating Procedures ................................................................................................10-40 Parts List ........................................................................................................................................10-42 Disassembly and Troubleshooting .................................................................................................10-43 SL-1 Injector Assembly .......................................................................................................10-44 Parts List ........................................................................................................................................10-44 Operation .......................................................................................................................................10-45 Auto Lube System ...............................................................................................................10-46 Filter/Regulator/Lubricator ..............................................................................................................10-46 Filter Maintenance and Repair .......................................................................................................10-47 Regulator Maintenance and Repair ...............................................................................................10-48 Lubricator Maintenance and Repair ...............................................................................................10-49 Pipe Thread Lubricator .......................................................................................................10-50 Air Service Unit ..............................................................................................................................10-50 Filter Regulator ...............................................................................................................................10-51 Air Line Regulator ..........................................................................................................................10-52 Pipe Thread Pump .........................................................................................................................10-53 Hammer Oiler Tank Assembly ............................................................................................10-61 Hammer Oiler Circuit ..........................................................................................................10.62

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Table of Contents

Section 10 Optional Equipment

Introduction xv Hammer Oil System ............................................................................................................10.63 Air Service Unit Components .........................................................................................................10-63 Filter Regulator ...............................................................................................................................10-64 Air Line Oiler ..................................................................................................................................10-65 Hammer Oil Pump ..........................................................................................................................10-66

Table of Contents BI620153

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).

1. Electronic Control Module (ECM)

2. Plug-Ins - Disconnect from ECM BEFORE welding.

SKF Safety 1-1

Section 1 Safety

Fig. 2-0a Electronic Control Module - Caterpillar 3412E Electronic Engine Fig. 2-0 Electronic Control Module - Caterpillar C-15 Electronic Engine

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2. Plug-Ins - Disconnect from ECM BEFORE welding.

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 minium 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 meters 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 meters of any electrical power line or underground utility without a permit indicating “danger zones” and minimum clearances.

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Safety

Clearances from Overhead High Voltage Lines

Clearances from High Voltage Lines

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

Contact With Electric Wires

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

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

● Do not attempt to leave the machine

● Follow site emergency procedures

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

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

Contaminated Air

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

DANGER: Contaminated air will cause severe injury or death

SKF Safety 1-3

Safety

Voltage Minimum Clearance up to 50 kv 10 ft. (3 m) over 50 to 75 kv 11 ft. (3.4 m) over 75 to 125 kv 13 ft. (4 m) over 125 to 175 kv 15 ft. (4.6 m) over 175 to 250 kv 17 ft. (5.2 m) over 250 to 370 kv 21 ft. (6.4 m) over 370 to 550 kv 27 ft. (8.2 m) over 550 to 1000 kv 42 ft. (12.8 m) BI620153

Safety Machine Stability

● The machine should never be propelled over areas that could potentially collapse or subside.

● Visual inspections of the path to be taken must be made

● All precautions relating to underground workings must be adhered to

● Never tram through areas of soft unconsolidated materials holding water

● If propelling on inclines is required, never travel across grades

● Do not tram the machine with the tower raised over rough or undulating ground

● Always ensure jacks are lowered onto solid stable ground

WARNING: Unit overturn can cause serious injury or death

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

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

1-4 SKF Safety

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

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

Moving and Rotating Parts

● The machine should not be operated unless all people are well clear of the area.

● The drill is designed for single person operation and no control should be activated with another person on the deck or in the vicinity of the machine unless clear communication methods have been established

● Do not lubricate or service while machine is running

WARNING: Moving parts can cause serious injury or death

High Pressure Air or Fluid

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

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

Before Operation

● Study and fully understand this manual.

● Wear all mandatory (ie safety helmet, eye protection, hearing protection) and other necessary Personal Protective Equipment when operating or working on or in the vicinity of the machine.

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

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

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

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

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Safety BI620153

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

● Be sure that the drill area is clear of all obstructions before operating the machine.

● Ensure that the safety chain is attached when using a towbar.

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

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

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

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

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

During Operation

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

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

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

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

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

1-6 SKF Safety

Safety

Dust Curtain Raised Auto Pulldown Off

BI620153

Emergency Stop

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

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

● Always check blind spots prior to propelling.

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

● Do not drill a hole so that any portion of the hole is closer than 6 meters to a hole containing explosives. Site rules may stipulate further distances.

● Ensure adequate ventilation when running the engine in an enclosed area. Exhaust gases contain carbon monoxide, a deadly poison which is colourless and odourless.

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

● Before lowering the mast, do make sure the carousel is rotated, locked in the non-pipe-loading centre position to ensure pipes are secured so they cannot possibly slide back and fall out of the carousel. Then swing the carousel in towards the centre of the mast.

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

● Do not climb the ladder to the operator cabin roof whilst the machine is running and always ensure secure footing.

● Do not under any circumstance climb the ladder giving access to the mast without wearing the appropriate safety harness. Only ever perform service work on the mast wearing approved fall arrest equipment.

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

● Do not propel the machine with the mast up.

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Safety

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Maintenance

● Be sure two personnel are present when performing live service work (machine running), both fully trained and competent in the safety issues. One person shall supervise from the operator’s position and have immediate access to an emergency stop in all situations. Visual, audible or verbal communication signals must be established and understood by both personnel prior to the commencement of work.

● Each person must be adequately trained to perform service and maintenance procedures.

● Place warning or danger tags and locks (or as per the site requirements) on starting controls to alert personnel that someone is working on the machine and disconnect battery before making repairs or adjustments to the machine.

● Be sure to have adequate lighting when performing service work at night.

● Relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.

● Be sure the machine and components are well supported before servicing or replacing parts.

● Always maintain metal-to-metal contact between the ﬁll nozzle and the fuel tank when ﬁlling the tank. This will prevent sparks and the possibility of an explosion.

● Do not strike the bit, or the drill pipe, with a hammer. Use only proper tools to make repairs or adjustments.

● Do not weld or grind near oil lines and always ensure the batteries are isolated prior to welding on the machine.

● Do not attempt to remove the radiator cap when the engine is hot or has overheated.

● When servicing the batteries, do not smoke or use an open ﬂame near the batteries. Batteries can give off hydrogen, which is a highly explosive gas.

● Be sure no tools or other loose objects are left on the engine, the drive mechanisms or the drilling platform as they could be thrown by this equipment with a powerful force.

If all or part of the equipment is shipped to a new destination, always include a complete instruction manual or a copy of the following topics:

● Safety Section

● Operation Instructions including:

● Pre-Start Checks

● Start Up

● After Start Checks

● Shutdown Procedure

● Propelling Machine

1-8 SKF Safety

Safety

Danger Tag

BI620153

Battery

Isolation Station

General Locator

O PE RATORS CABIN

FIRESUPPRESS ION ACTUACT OR

E /STOP

T RANSDUCERBOX

MAIN ELECTRICALCABINET

HYD TANK

FIRESUPPRESSIONTANKS

90LTQUELLT ANK

E/STOP

FIRESUPPRESSIONACTUACTOR

FIRE SUPPRESSION ACTUACTOR

E/STOP

EMERGENCY ACCESS LADDER

ISOLATORBOX

BATTE RY BOX

EMERGENCY ACCESS LADDER

E/STOP

FIRE SUPPRESSION ACTUACTOR

MAS T ACCESS LADDER

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90LT Q UE LLT ANK

MAS T ACCE SS L ADDER

AFE TY

E/STOP FIRE SUPPRESSION ACTUATOR

1-10 SKF Safety

Safety

TER EX

DUS T SKIRT ISO

General Locator LINE

LATO RBOX BATTE RY BOX

LIGHT LIGHTS

E/STOP

IRE

ACT

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F IRESUPPRESS ION TANKS MAST ACCESS LADDER

SUPP RESS ION

UACT OR

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