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
● 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 Drill Delivered :
Dealer : _____________________________________________
Customer : __________________________________________
ii SKSS Introduction
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Product Description
WARNING: DO NOT use this machine for any other purpose than blasthole drilling. Rotary blasthole drills are designed for blasthole drilling purposes only. Any other use could result in personal injury, property damage and will void the warranty.
The Reedrill Infinity Series is specifically designed for Blast Hole Drilling Operations.
The Infinity Series SKSS 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 29.5 inch (750mm) wide triple grouser shoes.
Manual Contents
This manual is furnished with your 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.
SKSS Introduction iii
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iv SKSS Introduction
Contents Introduction Parts Ordering & Product Support ............................................................................................i Safety Information ......................................................................................................................ii Product Description ..................................................................................................................iii Manual Contents .......................................................................................................................iii Table of Contents ......................................................................................................................iv General Locators ....................................................................................................................xvii Section 1 Safey .....................................................................................1-1 Personal Protective Equipment ..........................................................................................................1-2 Noise 1-2 Electrical Contact: 1-2 Overhead and Buried Utilities 1-2 Contact With Electric Wires 1-3 Contaminated Air ............................................................................................................................... 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 Safety Locators .......................................................................................................................1-9 Section 2 Operator’s Cab/ Controls ....................................................2-1 Operator’s Controls and Indicators .......................................................................................2-2 Control Panels ....................................................................................................................................2-2 Right Hand Control Panel .......................................................................................................2-3 Instrument Panel and Circuit Breakers .................................................................................2-4 Circuit Breakers ..................................................................................................................................2-4 Light Switches 2-5 Instrument Panel 2-5 System Pressure Guage Panel ..............................................................................................2-6 Left Hand Control Panel ......................................................................................................... 2-8 Foot Control Pedals .............................................................................................................. 2-14 Thread Grease Switch ........................................................................................................................14 Pipe Safety Arm Override Switch ........................................................................................................ 14 Air Conditioner .........................................................................................................................15 Contents ...........................................................................................................................................2-17 Introduction ......................................................................................................................................2-19 Unit Specification 2-20 Technical Data and Control Settings ................................................................................................2-23 Installation and Commissioning 2-25 Operating Instructions 2-32 Routine Maintenance Procedures 2-34 Fault Diagnosis 2-38 Warranty ........................................................................................................................................... 2-48 Basic Spare Parts Listing 2-49 Reference Drawings 2-51 BI620431
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SKSS Introduction v Table of Contents Section 3 Main Frame - Crawlers ........................................................3-1 Main Frame Repair ................................................................................................................ .3-2 Leveling Jacks .........................................................................................................................3-3 Leveling Jack Cylinders .....................................................................................................................3-4 Remove 3-4 Replace .............................................................................................................................................. 3-4 Mast Elevating Cylinders ........................................................................................................3-5 Remove ..............................................................................................................................................3-7 Replace 3-7 Crawler Assembly ...................................................................................................................3-8 Crawler Component Repair ................................................................................................................3-9 Metric Bolt Torque Specifications .......................................................................................3-10 Track Maintenance ................................................................................................................ 3-11 Before Operating Machine: ..............................................................................................................3-11 General Maintenance 3-11 Track Tension Adjustment ....................................................................................................3-12 Hydraulic Tensioner ..........................................................................................................................3-13 Correct Track Tension ......................................................................................................................3-13 Description 3-14 Nitrogen Tensioner ...........................................................................................................................3-15 Hydraulic Tensioner ..............................................................................................................3-16 Repair ...............................................................................................................................................3-16 Nitrogen Tensioner Assembly ..............................................................................................3-17 Track Tension Adjustment ....................................................................................................3-18 Nitrogen Tensioner - Filling Instructions ...........................................................................................3-18 Nitrogen Tensioner - Pressure Check ..............................................................................................3-20 Nitrogen Tensioner - Pressure Release ...........................................................................................3-20 Track Chain - Separate .........................................................................................................3-22 Track Chain Repair ................................................................................................................ 3-24 Track Link - Repair & Replace .........................................................................................................3-24 Track Link - Description ....................................................................................................................3-25 Track Shoes Installation .......................................................................................................3-26 Track Link Position ...........................................................................................................................3-26 Track Shoe - Mounting to Track Chain .............................................................................................3-26 Direct Torque Method .......................................................................................................................3-27 Torque Turn Method .........................................................................................................................3-27 Track Shoe - Retightening ................................................................................................................3-27 Track Shoe Bolt Torque (Direct Torque Method) ................................................................3-28 Track Shoe Bolt Torque (Torque Turn Method) .................................................................3-29 Track Chain and Shoe Installation ......................................................................................3-30 Track Chain with Shoes ...................................................................................................................3-30 Track Chain & Shoe - Assembly & Installation .................................................................................3-30 Final Drive ..............................................................................................................................3-32 Final Drive - General Description .....................................................................................................3-32 Final Drive Unit Removal ......................................................................................................3-33 Removal from Track Frame ..............................................................................................................3-33 Installation into Track Frame ............................................................................................................3-34 BI620431
vi SKSS Introduction
Final Drive Maintenance .......................................................................................................3-35 Oil Check / Change ..........................................................................................................................3-35 Final Drive Oil ........................................................................................................................3-36 Specifications ...................................................................................................................................3-36 Recommended Oil 3-36 Final Drive Assembly ............................................................................................................3-37 Parking Brake - Description .............................................................................................................3-38 Final Drive Disconnect .........................................................................................................3-39 Final Drive - Disconnect & Parking Brake ..........................................................................3-40 Towing Procedure - Gear Drive Disconnect .....................................................................................3-40 Parking Brake - Removal & Installation 3-40 Idler Assembly .......................................................................................................................3-41 Idler Unit Removal .................................................................................................................3-43 Idler Unit - Assembly .............................................................................................................3-45 Track and Support Rollers ................................................................................................... 3-49 General Description .........................................................................................................................3-49 Track Roller - Removal & Disassembly ............................................................................................3-51 Support Roller - Removal & Disassembly 3-52 Track and Support Roller - Assembly ...............................................................................................3-53 Track and Support Roller - Test and Install ......................................................................................3-54 Auxiliary Crane ......................................................................................................................3-56 Hiab Hydraulic Crane ......................................................................................................................3-56 Load Lift Capacities .........................................................................................................................3-56 Maintenance ..................................................................................................................................... 3-57 Fuel Tank Fill Assembly ........................................................................................................3-58 Hydraflo Fuel Fill ..............................................................................................................................3-58 Troubleshooting ................................................................................................................................3-59 Section 4 Engine / Drive Train / Compressor .....................................4-1 Power Group Locator .............................................................................................................4-2 Engine ...................................................................................................................................... 4-3 Engine Fuel System ...........................................................................................................................4-4 Oil Reserve Systems ........................................................................................................................4-12 Engine Oil Reserve System Circuit .................................................................................................. 4-12 Engine Oil Reserve System 4-12 LED Monitor Readings 4-13 Signals ............................................................................................................................................. 4-13 Adjustment of Running Oil Level 4-13 Wiring Diagram ................................................................................................................................4-14 Oil Pressure Switch ..........................................................................................................................4-14 Servicing 4-14 Troubleshooting ................................................................................................................................4-15 Oil Reserves Systems - Maintenance .............................................................................................. 4-15 Engine and Compressor Air Cleaners .................................................................................4-16 Engine and Compressor Air Cleaner Service ...................................................................................4-17 Inspection and General Service ....................................................................................................... 4-17 Engine and Compressor Air Cleaner Service ..................................................................................4-18 Safety Element Service ....................................................................................................................4-19 BI620431
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SKSS Introduction vii
Flexible Drive Coupling Service ..........................................................................................4-20 Adaptor Flanges ...............................................................................................................................4-20 Centering Flanges ............................................................................................................................ 4-20 Rubber Element 4-20 Tube Assembly .................................................................................................................................4-20 Mounting Screws and Adhesive .......................................................................................................4-21 Pump Drive ............................................................................................................................4-23 Pump Identification ...........................................................................................................................4-23 Pump Drive Assembly - Removal and Replacement .......................................................................4-24 Pump Drive Gearbox .............................................................................................................4-25 Pump Drive Gearbox - Repair ..........................................................................................................4-26 3" Input Shaft Assembly 4-28 Hydraulic Pumps ...................................................................................................................4-29 Compressor Installation .......................................................................................................4-30 Compressor Drive Coupling-Removal and Replacement ................................................................4-31 Compressor Unit - Installation ..........................................................................................................4-32 Before Start-Up of New or Rebuilt Compressor: .............................................................................. 4-34 Drill Compressor ...................................................................................................................4-35 High Pressure Compressor ................................................................................................. 4-36 Section 1 Safety ...............................................................................................................................4-36 General 4-36 Pressure Release ............................................................................................................................. 4-36 Fire and Explosion 4-37 Moving Parts 4-37 Toxic and Irritating Substances ........................................................................................................4-37 Electrical Shock ................................................................................................................................ 4-38 Lifting 4-38 Section 2 Description 4-39 Introduction ...................................................................................................................................... 4-39 Compressed Air Functions 4-39 Sullair Compressor Unit 4-40 Compressor Discharge System ....................................................................................................... 4-41 Compressor Cooling and Lubrication System 4-42 Compressor Fluid Circuit .....................................................................................................4-43 Compressor Condensation Table ........................................................................................ 4-46 Compressor Air Circuit 1475cfm @ 500psi .........................................................................4-47 Compressor Air Circuit .....................................................................................................................4-48 Compressor Functional Description ...................................................................................4-61 Air Inlet System ...............................................................................................................................4-61 Lubrication Guide 4-61 Application Guide 4-61 Capacity Control System With Poppet Valve, Functional Description ..............................................4-62 Start Mode ........................................................................................................................................4-62 Normal Operation ............................................................................................................................. 4-62 Modulating Mode 4-62 Unload Mode 4-62 Shutdown Mode ............................................................................................................................... 4-63 Instrument Group 4-63 Protection System ............................................................................................................................4-63 BI620431
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viii SKSS Introduction
Compressor Operation .........................................................................................................4-64 Section 3 Operation .........................................................................................................................4-64 General ............................................................................................................................................ 4-64 Purpose Of Controls 4-64 Initial Start-up Procedure 4-66 Subsequent Start-up Procedure ....................................................................................................... 4-67 Shutdown Procedure 4-67 General Operating Instructions 4-67 Compressor Maintenance ....................................................................................................4-68 Section 4 General Maintenance .......................................................................................................4-68 General ............................................................................................................................................ 4-68 Daily Operation 4-68 Maintenance After Initial 50 Hours Of Operation 4-69 Maintenance Every 250 Hours ......................................................................................................... 4-69 Maintenance Every 500 Hours 4-69 Maintenance Every 1000 Hours 4-69 Main Drive Shaft Seal Replacement ................................................................................................ 4-70 Interstage Tube ................................................................................................................................4-73 Discharge Check Valve ................................................................................................................... 4-74 Separator/Receiver Tank .................................................................................................................4-75 Minimum Pressure / Check Valve 4-77 Scavenge Line ............................................................................................................................... 4-78 Scavenge Line Sight Glass 4-78 Scavenge Line Oriface 4-78 Compressor Discharge Temperature Switches, Senders and Gauges ............................................4-79 Thermal/Bypass Valve 4-80 Fluid Stop Valve 4-82 Compressor Fluid Filter .................................................................................................................... 4-84 Inlet Valve 4-86 Compressor Regulation ................................................................................................................... 4-88 Relieving Regulators 4-88 Reducing Regulators 4-91 System Blowdown Valve ................................................................................................................. 4-93 Running Blowdown Valve 4-94 Moisture Separator Maintenance 4-96 Auxiliary Regulator ........................................................................................................................... 4-97 Troubleshooting ..............................................................................................................................4-101 Compressor Oil Cooler Assembly .....................................................................................4-105 Compressor oil cooler ....................................................................................................................4-105 Radiator/Hydraulic Oil Cooler Assembly ..........................................................................4-106 Radiator/Oil Cooler Repair ................................................................................................. 4-107 High Pressure Compressor Fluid Cooler .......................................................................... 4-109 Radiator Cooler ...................................................................................................................4-117 Section 5 Dust Control Systems .........................................................5-1 Water Injection .........................................................................................................................5-3 Water Tanks .......................................................................................................................................5-3 Water Tank Top-up Solenoid Valve.....................................................................................................5-4 Water Injection Relief Valve ...............................................................................................................5-6 BI620431
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SKSS Introduction ix
of Contents Water Injection Control .......................................................................................................................5-7 Basic Water Injection System - SKSS-15 5-9 Water Pump ..................................................................................................................................... 5-10 Pump Specifications 5-10 Servicing Instructions 5-10 Parts List 5-11 Recommended Lubricants 5-16 Water Injection Valve ........................................................................................................................5-17 Water Injection Ball Valve Assembly ................................................................................................5-17 Water Injection Ball Valve .................................................................................................................5-17 Actuator ............................................................................................................................................5-18 High Pressure Cleaner ..........................................................................................................5-31 Foam Injection ...................................................................................................................... 5-37 Section 6 Mast / Rotary Drive / Pipe Rack ..........................................6-1 Mast Weldment ........................................................................................................................6-2 Mast Repair ........................................................................................................................................6-2 Mast Assembly ........................................................................................................................6-3 Mast Pivot ..........................................................................................................................................6-4 Feed Cylinders ........................................................................................................................6-5 Feed Cylinder - Removal ...................................................................................................................6-7 Feed Cylinder Assembly .........................................................................................................6-9 Repair ...............................................................................................................................................6-10 Installation ........................................................................................................................................ 6-10 Hoist/Pulldown Cable Adjustment .......................................................................................6-11 Hoist/Pulldown Cable Replacement .................................................................................... 6-14 Rotary Drive Assembly .........................................................................................................6-16 Rotary Head Guide Alignment ..........................................................................................................6-17 Rotary Head Drive System ............................................................................................................... 6-18 Rotary Drive - Removal from Mast 6-19 Rotary Drive - Installation 6-19 Rotary Drive Gearbox ...........................................................................................................6-20 Rotary Drive Gearbox - Item Listing .................................................................................................6-21 Rotary Head Bull Shaft Bearing Nut ................................................................................................ 6-21 Rotary Drive Gearbox - Repair 6-22 Main Shaft Bearing Preload 6-22 Air Swivel ......................................................................................................................................... 6-23 Winch Assembly ....................................................................................................................6-24 Precautions on the Use of Winches .................................................................................................6-24 Wire Rope 6-24 Wedge Sockets 6-26 Grooved Drums ................................................................................................................................ 6-27 Plain (Smooth) Drums 6-27 Drums - Multiple Layers 6-27 Winch Assembly Service Manual .....................................................................................................6-28 Hydraulic Winch Repair 6-29 Deck Wrench..........................................................................................................................6-60 BI620431
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x SKSS Introduction
H.O.B.O. Wrench ...................................................................................................................6-61 Breakout System - HOBO ................................................................................................................6-62 Pipe Safety Arm ............................................................................................................................... 6-62 Pipe Positioner ......................................................................................................................6-63 Carousel Pipe Rack ...............................................................................................................6-64 Major Components ...........................................................................................................................6-64 Carousal Indexing 6-65 Pipe Rack Bearings - Removal ........................................................................................................ 6-67 Pipe Rack Components - Inspection 6-70 Pipe Rack - Assembly and Installation .............................................................................................6-71 Pipe Rack Roller - Remove and Replace ......................................................................................... 6-72 Pipe Rack Roller - Disassembly and Assembly 6-73 Section 7 Hydraulic Systems ..............................................................7-1 Hydraulic Symbols ..................................................................................................................7-2 Pressure Setting Sequence ....................................................................................................7-4 Hydraulic Tank ......................................................................................................................... 7-6 Return Hydraulic Filters ......................................................................................................................7-7 Main Return and Case Drain Filter ........................................................................................7-8 Main Hydraulic Pumps ..........................................................................................................7-10 Pump Identification ...........................................................................................................................7-10 Right Track, Left Track/Rotation Pumps .............................................................................7-11 Hydraulic Piston Pumps Removal and Repair .................................................................................7-11 Hydraulic Piston Pumps - Operation Specifications Adjustment and Repair ...................................7-11 HD/D Control 7-12 Technical Data ..................................................................................................................................7-14 Port Locations .................................................................................................................................. 7-18 Setting Procedure 7-19 Charge Pressure, High Pressure and P.O.R. Relief Settings ...........................................................7-20 Set Charge Pressure 7-20 Set Crossover Relief (High Pressure) 7-21 Set Pressure Override (P.O.R.) ........................................................................................................ 7-22 Mechanical Zero Position - HD Pump Control 7-23 Hydraulic Zero Position - HD Pump Control 7-24 Removal and Inspection of Charge Pump ....................................................................................... 7-25 Removal and Installation of Shaft Seal 7-26 Routine Maintenance 7-27 Charge Filter ..........................................................................................................................7-30 Routine Maintenance .......................................................................................................................7-30 Tram/Rotation Pump Circuit .................................................................................................7-32 Tram/Rotation Pump Circuit .............................................................................................................7-33 Rotation Circuit 7-34 Rotary Torque Control ......................................................................................................................7-34 Rotary Torque Control Circuit ...........................................................................................................7-36 Rotation/Tram Motor Circuit 7-37 Loop Filters ............................................................................................................................7-38 Rotary Drive Gearbox Motor ................................................................................................7-42 Rotary Drive Gearbox Motor - Test and Repair ................................................................................7-42 BI620431
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SKSS Introduction xi
Case leakage bypass test ................................................................................................................7-42 Shaft Seal Replacement 7-43 Trouble Shooting ..............................................................................................................................7-45 Feed and Auxiliary Pump Circuit .........................................................................................7-47 Hydraulic Piston Pumps Removal and Replacement .......................................................................7-47 Hydraulic Piston Pumps - Operation, Specifications, Adjustment and Repair .................................7-47 Feed & Auxiliary Functions Pump ...................................................................................................7-50 Function of Load Sensing Control (DRS) ......................................................................................... 7-50 Adjustment Procedure 7-50 Standby Pressure: 7-50 Main Pressure: ................................................................................................................................. 7-50 Repair Instructions - Shaft Seal 7-51 Pump Replacement Start Up 7-52 Auxiliary and Feed Circuits 7-53 Main Control Valves ..............................................................................................................7-54 Valve Stand Assembly ......................................................................................................................7-54 MP18 Valve - Jack and Mast Raise Valve ............................................................................7-55 MP22 Valve - Hoist and Pulldown Control ..........................................................................7-57 4WE6 - Aux. Functions and Mast Valves .............................................................................7-60 Exploded View of 4WE6 ...................................................................................................................7-63 Counterbalance Valve ...........................................................................................................7-64 Counterbalance Valve Adjustments .................................................................................................7-64 Pilot Control Manifold ...........................................................................................................7-65 Control Valve Assembly .......................................................................................................7-67 Auxiliary Pump Load Solenoid Valve - V03 ......................................................................................7-67 Shuttle Valve - V04 7-67 Auxiliary Pump Load Sense Relief - V05 7-67 Jacks/Mast raise Load Sense relief - V06 ........................................................................................ 7-68 Drill/Tram Interlock Solenoid Valve - V07 .........................................................................................7-68 Drill/Tram Solenoid Valve - V08 ......................................................................................................7-69 Auto Pulldown Solenoid Valve - V09 ................................................................................................ 7-69 Pilot Operated Directional Valve - V10 7-69 Set-up Interlock Solenoid Valve - V11 ..............................................................................................7-69 Auto Pulldown Pressure Reducing Valve - V12 7-70 Shuttle Valve - V13 7-70 Surge Protection Relief Valve - V14 .............................................................................................. 7-70 Maximum Pulldown Pressure Relief - V15 7-71 2nd Maximum Pulldown Relief Valve - V16 7-71 Reduced Pulldown Relief Valve - V17 .............................................................................................. 7-71 Reduced Pulldown Solenoid Valve - V18 7-71 Shuttle Valve - V19 7-72 Orifice - V20 ..................................................................................................................................... 7-72 Maximum Rotation Pressure Relief - V21 7-72 Surge Protection Pressure Reducing/Relieving Valve - V22 ............................................................7-72 Feed Valve Assembly ............................................................................................................7-73 Hoist/Pulldown Control Valve 410665 MP22 ...................................................................................7-73 Set Max. Pulldown Relief Valve (V15) ............................................................................................. 7-73 Feed Control Valve 7-61 BI620431
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xii SKSS Introduction
Contents Hydraulic Feed Circuit ..........................................................................................................7-76 Holdback Control .................................................................................................................. 7-81 Jack Control and Mast Elevating Circuit ............................................................................ 7-82 Pressure Adjustment ........................................................................................................................7-83 Leveling Jack Cylinders .......................................................................................................7-84 Jack Leg Cylinder .............................................................................................................................7-84 Counterbalance Valve Test Procedure .............................................................................................7-85 Mast Elevating Cylinders ......................................................................................................7-86 Counterbalance Valve Test Procedure .............................................................................................7-87 Auxiliary Functions Circuit ..................................................................................................7-88 Hydraulic Operated Breakout Wrench ................................................................................ 7-90 Setting of HOBO Sequence Valves ..................................................................................................7-91 Pipe Positioner Sequence Valves ........................................................................................7-92 Setting of Pipe Positioner Sequence Valves ....................................................................................7-92 Pipe Safety Arm Sequence Valves .......................................................................................7-93 Setting of Pipe Safety Arm Sequence Valves ..................................................................................7-93 Hydraulic Gear Pumps ..........................................................................................................7-94 Hydraulic Gear Pumps - Repairs Operation Specifications and Adjustment ....................................7-94 Shaft Seal Removal and Replacement 7-95 Cooler Fan Circuit .................................................................................................................7-97 Fan Motor Circuit ..............................................................................................................................7-97 Adjustment .......................................................................................................................................7-97 Cooler Fan Motor ................................................................................................................7-100 Hydraulic Thermostatic Valve ............................................................................................ 7-104 Central Lube ........................................................................................................................7-105 Hydraulic Circuit .............................................................................................................................7-106 Air Conditioner Compressor Drive Circuit .......................................................................7-107 Air Conditioner Drive Motor ............................................................................................... 7-108 Water Injection Circuit ........................................................................................................7-112 Water Injection valve ......................................................................................................................7-113 Water Injection Electrical Circuit .....................................................................................................7-114 Toc-2 Controller ..............................................................................................................................7-114 Water Injection Valve ..........................................................................................................7-115 Water Pump Motor ..............................................................................................................7-132 Shaft Seal Repair ...........................................................................................................................7-133 Hydraulic Cylinders Repair ................................................................................................7-136 Hydraulic Cylinders List ..................................................................................................................7-136 Section 8 Vigilante Guide and Electrical Components .....................8-1 Electrical Locator ....................................................................................................................8-2 Batteries ................................................................................................................................... 8-5 Jump Starting .......................................................................................................................... 8-6 Welding Precautions ...............................................................................................................8-8 Vigilante Guide ........................................................................................................................8-9 Contents .............................................................................................................................................8-9 Important Information .......................................................................................................................8-10 BI620431
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SKSS Introduction xiii
PLC ..................................................................................................................................................8-11 Run/Rem/Program Key-switch 8-11 Eeprom .............................................................................................................................................8-12 Recover From A Processor Fault .....................................................................................................8-12 Output Card ......................................................................................................................................8-13 Replacing A Faulty Card ...................................................................................................................8-13 Analog Card Configuration ...............................................................................................................8-13 Touchscreen .....................................................................................................................................8-14 Setting The Date and Time ..............................................................................................................8-14 Changing A CF Card ........................................................................................................................8-14 Setting Brightness ............................................................................................................................ 8-14 Laser Depth System 8-15 General Info .....................................................................................................................................8-15 Functional Description of Operation ................................................................................................. 8-15 Setting up the Laser 8-15 Safety Instructions & Precautions 8-16 Calibration 8-16 Pipe in Hole Detection (option) 8-17 Pipe Rack Swing Interlock ............................................................................................................... 8-17 Distance Meter 8-17 Setting Up 8-17 Start Up and Shut Down .................................................................................................................. 8-18 Idle Timer .........................................................................................................................................8-18 Hydraulic Function Enable 8-18 Drill Tram Enable Function ...............................................................................................................8-18 Alarms ..............................................................................................................................................8-18 Shutdown Alarms 8-18 Indication Only Alarms ..................................................................................................................... 8-19 Filter Bypass Indication Only Alarms 8-19 Solenoid Control ............................................................................................................................... 8-19 Drill / Tram Solenoid (Off to Tram / On to Drill) ................................................................................8-19 Drill / Tram Interlock Solenoid (On to Tram / On to Drill) ..................................................................8-19 Tram Conditions OK ......................................................................................................................... 8-20 Drill Conditions 8-20 Setup Interlock Solenoid (On to operate Jacks and Mast) 8-21 Pipe Rack Pressure Reduce Solenoid (On to reduce pull-down pressure) ..................................... 8-21 Aux Priority Solenoid (On to load Aux pressure) ..............................................................................8-21 Pipe Rack Swing In interlock 8-21 Dust Curtain Raise Solenoid ............................................................................................................ 8-21 Pipe Positioner Kickout Solenoid 8-21 Washdown Solenoid .........................................................................................................................8-22 Auto Lube 8-22 Operation 8-22 Hammer Oiler System ...................................................................................................................... 8-22 Auto Mode ........................................................................................................................................8-22 Manual Mode 8-22 Gauges ............................................................................................................................................. 8-23 General Info .....................................................................................................................................8-23 Operation checks 8-23 Pressure Transducer 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xiv SKSS Introduction
Level Transducer ..............................................................................................................................8-23 Hammer Oil Level Transducer .........................................................................................................8-23 Temperature Transducer ..................................................................................................................8-24 Water Flow Transducer ....................................................................................................................8-24 Inclinometers 8-25 Head Speed Module 8-28 General info 8-28 Calibrating ........................................................................................................................................ 8-28 Level Switches 8-29 Dust Suppression 8-29 Water Injection ................................................................................................................................. 8-29 Turkey Spray 8-29 Water Suppression Tank - Top Up ....................................................................................................8-29 Head Speed Module ..............................................................................................................8-31 Inclinometer ...........................................................................................................................8-33 Ladder Prox Switch ............................................................................................................... 8-36 Laser ....................................................................................................................................... 8-37 Level Switches ......................................................................................................................8-49 Radiator Level Switch ...........................................................................................................8-53 Level Transducers ................................................................................................................. 8-57 Hammer Oil Level Transducer ............................................................................................. 8-67 Pressure Transducers ..........................................................................................................8-69 Temperature Transducer ......................................................................................................8-78 Temperature Sensor.............................................................................................................. 8-90 Water Flow Transducer .........................................................................................................8-91 Water Control Module .........................................................................................................8-105 Rod Counter Prox Switch ................................................................................................... 8-112 Remote Fuel Level Display .................................................................................................8-113 Section 9 Lubrication and Preventive Maintenance .........................9-1 Central Lube System ..............................................................................................................9-2 Hydraulic Control Schematic ..............................................................................................................9-3 Auto Lube 9-3 Central Lube System Circuit Drawing ...................................................................................9-5 Central Lube Tank Assembly .................................................................................................9-6 Central Lube System ..............................................................................................................9-7 Central Lube Pump Module ...............................................................................................................9-8 Central Lube Pump 9-21 SL-1 Injector Assembly 9-46 SL-1 Injector Specifications .............................................................................................................. 9-46 Hammer Oiler Tank Assembly ..............................................................................................9-48 Hammer Oil Circuit ................................................................................................................9-49 Hammer Oil System .............................................................................................................. 9-50 Air Service Unit Components ...........................................................................................................9-50 Filter Regulator 9-51 Air Line Oiler 9-52 BI620431
Table of Contents
SKSS Introduction xv Table of Contents Pipe Thread Lubricator .........................................................................................................9-70 Air Service Unit ................................................................................................................................9-70 Filter Regulator ................................................................................................................................. 9-71 Air Line Lubricator 9-72 Pipe Thread Pump ...........................................................................................................................9-73 Filter Locator .........................................................................................................................9-81 Lubrication And Maintenance .............................................................................................. 9-83 Safety ...............................................................................................................................................9-83 Track Gear 9-83 Engine Maintenance 9-84 Air Cleaners ..................................................................................................................................... 9-85 Air Filter Elements 9-85 Alternator Maintenance 9-85 Pump Drive And Drive Shaft Maintenance ......................................................................................9-86 Compressor Maintenance 9-86 Cooler Packs .................................................................................................................................... 9-87 A-Frame And Pivot Point Maintenance ............................................................................................9-87 Pull Down And Hoist Ropes And Sheaves Maintenance ................................................................9-88 Rotary Head Maintenance .............................................................................................................. 9-88 Hydraulic System Maintenance 9-89 Hydraulic Maintenance 9-89 Water Pump Maintenance ...............................................................................................................9-90 Cab Maintenance 9-90 Air Conditioner Maintenance 9-90 Battery Maintenance ........................................................................................................................ 9-91 Lubrication System Maintenance 9-91 Fire Suppression Maintenance ....................................................................................................... 9-91 Lubrication - General ............................................................................................................9-92 Equipment Lubrication .....................................................................................................................9-92 Lubrication & Maintenance Chart - 250hr ...........................................................................9-93 Lubrication & Maintenance Chart - 500hr .........................................................................9-103 Lubrication & Maintenance Chart - 1000hr .......................................................................9-114 Lubrication & Maintenance Chart - 2000hr ....................................................................... 9-125 Lubrication and Maintenance ............................................................................................ 9-137 Lubricant Specifications .................................................................................................... 9-138 Hydraulic System ...........................................................................................................................9-138 Hydraulic Tank Capacity .................................................................................................................9-138 Compressor Lubrication 9-139 Lubricating Grease ......................................................................................................................... 9-140 Gear Lubricant 9-140 Scheduled Oil Sampling Analysis ...................................................................................................9-140 Torque Values for Split Flange Connections ....................................................................9-141 Torque Values for Hydraulic Tubes & Fittings ..................................................................9-142 Torque Values for Standard Fasteners..............................................................................9-143 BI620431
xvi SKSS Introduction
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General Locator
SKSS Introduction xvii General Locator BI620431
xviii SKSS Introduction
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General Locator
SKSS Introduction xix Notes BI620431
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).
SKSS Safety 1-1 Section 1
Safety
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Safety
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.
1-2 SKSS Safety
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DANGER: If contact with the machine and power lines should occur it will cause severe injury or death
Contact With Electric Wires
You should observe the following points if the drill comes into contact with live electrical cables:
● Do not allow any other personnel to touch any part of the machine whilst standing on the ground until the power has been isolated
● Do not attempt to leave the machine
● Follow site emergency procedures
DANGER: Wait until the power has been switched off before attempting to leave or move the machine
Under most circumstances, you should remain seated or in the position you were in when contact was made. If, however, circumstances (such as fire) make it necessary to leave the machine, then you should JUMP clear and as far as possible from the drill. The critical factor in leaving the machine is the danger of your body completing the electrical circuit, from the power line and the machine, to the ground.
Contaminated Air
Diesel fumes are toxic. Exhaust gasses contain carbon monoxide, a deadly poison, which is colourless and odourless. Therefore, do not run the machine in an area without good ventilation. Compressed air is toxic and should never be directly inhaled.
DANGER: Contaminated air will cause severe injury or death
SKSS Safety 1-3
Safety BI620431
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 SKSS 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.
SKSS Safety 1-5
Safety BI620431
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