CAT Bucyrus Terex SKSS-15 Infinity Blasthole Drill Service Manual SN1K67X13 – PDF DOWNLOAD by www.heydownloads.com

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

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

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

2. PART NUMBER AND DESCRIPTION

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

3. SHIPMENT

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

MAILING ADDRESSFOR PARTS ORDER ENTRY SHIPPING ADDRESS Terex Reedrill WA Terex Reedrill WA Terex Reedrill WA P. O. Box 1006 Telephone (08) 9495 7700 Lot 21 Brant Rd Kelmscott WA, 6111 Fax (08) 9495 7750 Kelmscott WA, 6111 AUSTRALIAN BRANCHES Brisbane Newcastle Mackay 585 Curtain Ave East 139 Racecourse Rd 10-12 Corporate Dve Eagle Farm QLD 4009 Rutherford NSW 2320 Mackay QLD 4740 Ph. (07) 3632 4600 Ph. (02) 4932 0000 Ph. (07) 4953 5600 Fax. (07) 3216 3934 Fax (02) 4932 0733 Fax (07) 4952 5311 © TEREX REEDRILL 2007

SKSS Introduction Int-3

BI620424

iv SKSS Introduction Contents Introduction....................................................................................Int-2 Safety Information ........................................................................................................................Int-2 Parts Ordering and Product Support ..........................................................................................Int-3 Table of Contents ...............................................................................................................................iv General Locator ...............................................................................................................................xvi Section 1 - Safety..............................................................................1-1 Section 1 Contents .........................................................................................................................1-3 Safety ...............................................................................................................................................1-4 Personal Protective Equipment ..................................................................................................1-4 Noise ..........................................................................................................................................1-4 Electrical Contact .......................................................................................................................1-4 Overhead and Buried Utilities.....................................................................................................1-4 Contact with Electric Wires .........................................................................................................1-5 Contaminated Air ........................................................................................................................1-5 Machine Stability ........................................................................................................................1-6 Moving and Rotating Parts .........................................................................................................1-7 High Pressure Air or Fluid ..........................................................................................................1-7 Before Operation ........................................................................................................................1-7 During Operation ........................................................................................................................1-8 Maintenance .............................................................................................................................1-10 Safety Locator ...........................................................................................................................1-11 Section 2 - Operator's Cab / Controls .............................................2-1 Section 2 Contents .........................................................................................................................2-3 Graphic Symbol Legend ................................................................................................................2-4 Warning Decals ...............................................................................................................................2-8 Operators Controls and Indicators .............................................................................................2-10 Control Panels ..........................................................................................................................2-10 Right Hand Control Panel .............................................................................................................2-11 Instrument Panel and Circuit Breakers ......................................................................................2-12 Circuit Breakers ........................................................................................................................2-12 Light Switches ..........................................................................................................................2-13 Instrument Panel ......................................................................................................................2-13 System Pressure Guage Panel ....................................................................................................2-14 Left Hand Control Panel ...............................................................................................................2-16 Foot Control Pedals ......................................................................................................................2-22 Cab Foot Controls ....................................................................................................................2-22 Thread Grease Switch..............................................................................................................2-22 Pipe Safety Arm Override Switch .............................................................................................2-22 Air Conditioner ..............................................................................................................................2-23 T8 Series Split System Air Conditioning Manual ......................................................................2-23 Section 3 - Main Frame / Crawlers ..................................................3-1 Section 3 Contents .........................................................................................................................3-3 Main Frame Repair - General .........................................................................................................3-5 BI620424

SKSS Introduction v Contents Main Frame Repair .....................................................................................................................3-5 Leveling Jacks ................................................................................................................................3-6 Leveling Jacks ............................................................................................................................3-6 Leveling Jack Cylinders ..............................................................................................................3-7 Mast Elevating Cylinders ...............................................................................................................3-8 Mast Elevating Cylinders ............................................................................................................3-9 Remove ....................................................................................................................................3-10 Repair .......................................................................................................................................3-10 Replace ....................................................................................................................................3-10 Crawler Assembly ..........................................................................................................................3-11 Crawler Component Repair ......................................................................................................3-12 Metric Bolt Torque Specifications ...............................................................................................3-13 Track Maintenance........................................................................................................................3-14 Before Operating the Machine .................................................................................................3-14 General Maintenance ...............................................................................................................3-14 Track Tension Adjustment ...........................................................................................................3-15 Hydraulic Tensioner ..................................................................................................................3-16 Description ...............................................................................................................................3-17 Nitrogen Tensioner ...................................................................................................................3-18 Hydraulic Tensioner .....................................................................................................................3-19 Repair .......................................................................................................................................3-19 Nitrogen Tensioner Assembly .....................................................................................................3-20 Nitrogen Tensioner - Fitting Instructions ...................................................................................3-21 Nitrogen Tensioner - Pressure Check ......................................................................................3-23 Nitrogen Tensioner - Pressure Release ...................................................................................3-23 Track Chain - Separate .................................................................................................................3-24 Track Chain - Repair .....................................................................................................................3-25 Track Link - Repair & Replace..................................................................................................3-25 Track Link - Description ............................................................................................................3-26 Track Shoes Installation...............................................................................................................3-27 Track Link Position ...................................................................................................................3-27 Track Shoe - Mounting to Tracsk Chain ...................................................................................3-28 Track Shoe Bolt Torque (Direct Torque Method) .......................................................................3-29 Track Shoe Bolt Torque (Torque Turn Method) .........................................................................3-30 Track Chain and Shoe Installation ..............................................................................................3-31 Track Chain with Shoes............................................................................................................3-31 Track Chain & Shoe - Assembly & Installation .........................................................................3-31 Final Drive .....................................................................................................................................3-33 Removal from Track Frame ......................................................................................................3-33 Final Drive Assembly ................................................................................................................3-34 Final Drive Service ...................................................................................................................3-36 Final Drive Installation ..............................................................................................................3-58 Idler Unit Assembly ......................................................................................................................3-59 Idler Unit - Assembly ................................................................................................................3-61 Idler Unit Removal ........................................................................................................................3-65 Idler Unit - Removal ..................................................................................................................3-65 BI620424

vi SKSS Introduction Contents Track and Support Rollers ...........................................................................................................3-67 General Description..................................................................................................................3-67 Track Roller - Removal & Disassembly ....................................................................................3-69 Track and Support Roller - Assembly .......................................................................................3-71 Track and Support Roller - Test and Install ..............................................................................3-72 Auxiliary Crane .............................................................................................................................3-74 Hydraulic Crane (Auxiliary Crane) ............................................................................................3-74 Load Lift Capacities ..................................................................................................................3-74 Maintenance .............................................................................................................................3-75 Section 4 - Engine / Drive Train / Compressor...............................4-1 Section 4 Contents .........................................................................................................................4-3 Power Group Locator .....................................................................................................................4-6 Cummins Engine ............................................................................................................................4-7 Engine Fuel System ...................................................................................................................4-8 Construction ...............................................................................................................................4-9 Combo Fuel Filter Head & Pump Manifold ...............................................................................4-10 FS1006 Fuel Filter with Water Separator .................................................................................4-10 Fuel Manifold with Integrated FSO Valve ..................................................................................4-11 Fuel Connections ......................................................................................................................4-11 Pre Filters .................................................................................................................................4-12 Wiring with EFS Power Relay ..................................................................................................4-12 Pressure and Temperature Sensors .........................................................................................4-12 Operation ..................................................................................................................................4-13 QST30 Electric Fuel Supply System ........................................................................................4-14 Oil Reserve Systems ................................................................................................................4-16 Engine Oil Reserve System (Basic Circuit) ..............................................................................4-16 LED Monitor Readings .............................................................................................................4-17 Adjustment of Running Oil Level ..............................................................................................4-17 Oil Reserve Basic Circuit ..........................................................................................................4-18 Oil Pressure Switch ..................................................................................................................4-18 Oil Reserve System ..................................................................................................................4-18 Troubleshooting ........................................................................................................................4-19 Maintenance .............................................................................................................................4-19 Engine and Compressor Air Cleaner ..........................................................................................4-20 Engine and Compressor Air Cleaner Service ...........................................................................4-21 Compressor Assembly .................................................................................................................4-24 Flexible Drive Coupling ................................................................................................................4-25 Flexible Drive Coupling Service ...............................................................................................4-25 Pump Drive ....................................................................................................................................4-27 Pump Identification ...................................................................................................................4-27 Pump Drive Assembly - Removal and Replacement................................................................4-28 Pump Drive Gearbox ....................................................................................................................4-29 Pump Drive Gearbox Repair ....................................................................................................4-30 3" Input Shaft Assembly ...........................................................................................................4-32 Hydraulic Pump ............................................................................................................................4-33 BI620424

SKSS Introduction vii Contents Hydraulic Pumps - Removal and Replacement........................................................................4-33 Compressor Installation ...............................................................................................................4-34 Compressor Drive Coupling .....................................................................................................4-34 Compressor Drive Coupling - Removal and Replacement.......................................................4-38 Compressor Shaft Seal ................................................................................................................4-40 Compressor Shaft Seal ............................................................................................................4-40 High Pressure Compressosr .......................................................................................................4-43 Safety .......................................................................................................................................4-43 Description ...............................................................................................................................4-46 Compressed Air Functions .......................................................................................................4-46 Compressor Oil Circuit ................................................................................................................4-50 Diagram Legend .......................................................................................................................4-50 Compressor Oil Circuit - COLD ................................................................................................4-51 Compressor Oil Circuit - HOT ..................................................................................................4-52 Compressor Condensation Table ...............................................................................................4-53 Compressor Air Circuit ................................................................................................................4-54 Compressor Air Circuits - 1475cfm @ 500psi ..........................................................................4-54 Compressor Functional Description ...........................................................................................4-69 Compressor Operation .................................................................................................................4-72 Operation ..................................................................................................................................4-72 Compressor Maintenance ............................................................................................................4-75 General Maintenance ...............................................................................................................4-75 Interstage Tube ........................................................................................................................4-77 Discharge Check Valve ............................................................................................................4-78 Separator/Receiver Tank ..........................................................................................................4-79 Scavenge Line..........................................................................................................................4-81 Compressor Discharge Temperature Gauge, Switch and Sender ...........................................4-82 Minimum Pressure Valve ..........................................................................................................4-83 Minimum Pressure / Check Valve Maintenance .......................................................................4-83 Thermal Bypass Valve ..............................................................................................................4-84 Thermal Bypass Valve Maintenance ........................................................................................4-85 Oil Stop Valve ...........................................................................................................................4-86 Compressor Fluid Filter ............................................................................................................4-88 Changing Filter Elements .........................................................................................................4-89 Inlet Valve .................................................................................................................................4-90 Relieving Regulators ................................................................................................................4-92 Reducing Regulators ................................................................................................................4-95 System Blowdown Valve ..........................................................................................................4-97 Running Blowdown Valve .........................................................................................................4-98 Running Blowdown Maintenance .............................................................................................4-99 Moisture Separator Maintenance ...........................................................................................4-100 System Air Dryer ....................................................................................................................4-101 Airodyn Compressed Air Drain Trap Installation.....................................................................4-102 Airodyn Compressed Air Drain Trap Operation ......................................................................4-102 Airodyn Compressed Air Drain Trap Maintenance .................................................................4-103 Auxiliary Regulators ...............................................................................................................4-104 BI620424

viii SKSS Introduction Contents Auxiliary Regulator Maintenance............................................................................................4-106 Troubleshooting ......................................................................................................................4-108 Cooler Locator .............................................................................................................................4-111 Compressor Oil Cooler Assembly ..............................................................................................4-112 Hydraulic Oil / Radiator Cooler Assembly .................................................................................4-113 Coolers Maintenance ...................................................................................................................4-114 Compressor Oil / Hydraulic Oil Cooler Service Manual ...........................................................4-115 Radiator Cooler Service Manual ................................................................................................4-122 Section 5 - Dust Control System .....................................................5-1 Dust Control System ......................................................................................................................5-4 Dust Control Systems .................................................................................................................5-4 Water Injection ................................................................................................................................5-5 Water Tanks................................................................................................................................5-5 Water Tank Top up Soleniod Valve .............................................................................................5-6 Water Injection Relief Valve........................................................................................................5-8 Water Injection Control ...............................................................................................................5-9 Water Injection Basic Circuit......................................................................................................5-11 Water Pump ...................................................................................................................................5-12 Pump Specifications .................................................................................................................5-12 Servicing Instructions ...............................................................................................................5-12 Parts List ..................................................................................................................................5-13 Replacing Piston Cup Seals .....................................................................................................5-14 Replacing Suction and Discharge Valves .................................................................................5-15 Replacing Power End Bearings................................................................................................5-16 Servicing the Wrist Pin Bearings ..............................................................................................5-17 Fastener Torque Requirements ................................................................................................5-17 Recommended Lubricants .......................................................................................................5-18 Water Pump Motor Repair ........................................................................................................5-18 Water Injection Hydraulic Control Valve Repair........................................................................5-18 Water Pump Drive Coupling .....................................................................................................5-18 Level and Flow Transducer ......................................................................................................5-18 High Pressure Cleaner .................................................................................................................5-19 High Pressure Wash down (Motor and Pump) .........................................................................5-19 Water Injection Valve ....................................................................................................................5-25 Water Injection Ball valve assembly .........................................................................................5-25 Water Injection Ball valve .........................................................................................................5-25 Actuator - Installation Operation and Maintenance Manual .....................................................5-27 Actuator - Contents ..................................................................................................................5-28 Actuator - Air Connections........................................................................................................5-29 Actuator - Installation................................................................................................................5-30 Actuator - Dis-assembly ...........................................................................................................5-31 Actuator - Removing Endcaps type ES ....................................................................................5-32 Actuator - Removing Pistons/Spindle .......................................................................................5-33 Actuator - Re-assembly guide band and shaft .........................................................................5-33 Actuator - Reassembly Pistons ................................................................................................5-34 BI620424

SKSS Introduction ix Contents Actuator - Re-assembly Endcaps single acting actuators ........................................................5-35 Actuator - Re-assembly of springclip and insert .......................................................................5-36 Actuator - Parts List ..................................................................................................................5-37 Section 6 - Mast / Rotary Drive / Pipe Rack....................................6-1 Section 6 Contents .........................................................................................................................6-3 Mast Weldment................................................................................................................................6-4 Mast Repair ................................................................................................................................6-4 Mast Assembly ................................................................................................................................6-5 Mast Assembly ...........................................................................................................................6-5 Mast Pivot ...................................................................................................................................6-6 Feed Cylinders ................................................................................................................................6-7 Feed Cylinder - Removal ............................................................................................................6-9 Feed Cylinder Assembly............................................................................................................6-11 Repair .......................................................................................................................................6-12 Installation ................................................................................................................................6-12 Hoist / Pulldown Cable Adjustment ............................................................................................6-13 Hosit / Pulldown Cable Adjustment ..........................................................................................6-14 Hoist / Pulldown Cable Replacement .......................................................................................6-17 Rotary Drive Assembly .................................................................................................................6-18 Rotary Head Guide Alignment ..................................................................................................6-19 Rotary Head - Drive System .....................................................................................................6-20 Rotary Drive - Removal from Mast ...........................................................................................6-21 Rotary Drive - Installation .........................................................................................................6-21 Rotary Drive Gearbox ...................................................................................................................6-22 Rotary Drive Gearbox - Item Listing .........................................................................................6-23 Rotary Head Bull Shaft Bearing Nut .........................................................................................6-23 Rotary Drive Gearbox - Repair .................................................................................................6-24 Air Swivel ..................................................................................................................................6-25 Winch Assembly ...........................................................................................................................6-26 Precautions on the use of Winches ..........................................................................................6-26 Wedge Socket ..........................................................................................................................6-28 Grooved Drums ........................................................................................................................6-29 Plain (Smooth) Drums ..............................................................................................................6-29 Drums - Multiple Layers ...........................................................................................................6-29 Winch Assembly Service ..........................................................................................................6-30 BG8A and BG8B Hydraulic Winch Service Manual..................................................................6-31 Deck Wrench .................................................................................................................................6-62 H.O.B.O. Wrench ...........................................................................................................................6-63 Breakout System - HOBO ........................................................................................................6-64 Pipe Safety Arm........................................................................................................................6-64 Pipe Positioner ..............................................................................................................................6-65 Carousel Pipe Rack ......................................................................................................................6-66 Major Components ...................................................................................................................6-66 Rod Handling - Carousel Indexing ...........................................................................................6-67 Carousel Pipe Rack Assembly .................................................................................................6-68 BI620424

x SKSS Introduction Contents General Information..................................................................................................................6-69 Pipe Rack Bearings - Removal ................................................................................................6-69 Pipe Rack Componetns - Inspection ........................................................................................6-72 Pipe Rack - Assembly and Installation .....................................................................................6-73 Pipe Rack Roller - Remove and Replace .................................................................................6-74 Pipe Rack Roller - Disassembly and Assembly........................................................................6-75 Section 7 - Hydraulic Systems ........................................................7-1 Section 7 Contents .........................................................................................................................7-3 Hydraulic Symbols .........................................................................................................................7-6 Pressure Setting Sequence ...........................................................................................................7-8 Pressure Setting Sequence........................................................................................................7-8 Hydraulic Tank ..............................................................................................................................7-10 Hydraulic Tank ..........................................................................................................................7-10 Return Hydraulic Filters .............................................................................................................7-11 Main Return and Case Drain Filters ............................................................................................7-12 Routine Maintenance ...............................................................................................................7-13 Changing Filter Elements .........................................................................................................7-13 Main Hydraulic Pumps .................................................................................................................7-14 Pump Identification ...................................................................................................................7-14 Right Track, Left Track / Rotation Pumps ..................................................................................7-15 Hydraulic Piston Pumps - Removal and REplacement ............................................................7-15 AA4VG 180 Hydraulic Pump HD/D Control..............................................................................7-16 Technical Data ..........................................................................................................................7-18 Port Locations ..........................................................................................................................7-22 Setting Procedure.....................................................................................................................7-23 Charge Pressure, High Pressure, P.O.R. and Zero Position Settings ......................................7-24 Set Charge Pressure - 450psi (31 bar) ....................................................................................7-24 Set Crossover Relief (High Pressure) - 5500psi (380 bar) .......................................................7-25 Set Pressure Override (P.O.R) - 5000psi (345 bar) ..................................................................7-26 Set Mechanical Zero Position - HD Pump Control ...................................................................7-27 Set Hydraulic Zero Position - HD Pump Control ......................................................................7-28 Removal and Inspection of Charge Pump................................................................................7-29 Removal and Installation of Shaft Seal ....................................................................................7-30 Routine Maintenance ...............................................................................................................7-31 Charge Filter ..................................................................................................................................7-34 Routine Maintenance ...............................................................................................................7-34 Changing Filter Elements .........................................................................................................7-34 Main Pumps Circuit ......................................................................................................................7-36 Main Pumps Circuit ..................................................................................................................7-36 Rotation/Tram Motor Circuit .....................................................................................................7-37 Loop Filters ...................................................................................................................................7-38 Routine Maintenance ...............................................................................................................7-38 Changing Filter Elements .........................................................................................................7-41 Rotation Circuit .............................................................................................................................7-42 Rotation Circuit .........................................................................................................................7-42 BI620424

SKSS Introduction xi Contents Rotary Drive Gearbox Motor ........................................................................................................7-44 Rotary Drive Gearbox Motor - Test and Repair ........................................................................7-44 Shaft Seal Replacement...........................................................................................................7-45 Trouvle Shooting ......................................................................................................................7-47 Tram Circuit ...................................................................................................................................7-49 Tram Circuit ..............................................................................................................................7-49 Feed and Auxiliary Pump Circuit .................................................................................................7-51 Hydraulic Piston Pumps - Removal and Replacement.............................................................7-51 Feed and Auxiliary Functions Pump .........................................................................................7-54 Repair Instructions ...................................................................................................................7-55 Pump Replacement - Start Up .................................................................................................7-56 Hydraulic Systems ........................................................................................................................7-58 Auxiliary and Feed Circuits .......................................................................................................7-58 Main Control Valves ......................................................................................................................7-59 Valve Stand Assembly ..............................................................................................................7-59 Pilot Control Manifold...................................................................................................................7-60 Control Valve Assembly ...............................................................................................................7-62 Auxiliary Pump Load Solenoid Valve ........................................................................................7-62 Hydraulic Feed Circuit ..................................................................................................................7-68 MP22 Valve - Hoist and Pulldown Control ..................................................................................7-70 Feed Valve Assembly ...................................................................................................................7-73 Holdback Control ..........................................................................................................................7-76 Jack Control and Mast Elevating Circuit ....................................................................................7-77 Jack Control and Mast Elevating Circuit...................................................................................7-78 MP18 Valve - Jack and Mast Raise Valve....................................................................................7-79 Counterbalance Valves ................................................................................................................7-81 Counterbalance Valve Adjustment ...........................................................................................7-81 Leveling Jack Cylinders ...............................................................................................................7-82 Counterbalance Valve Test Procedure .....................................................................................7-83 Mast Elevating Cylinders .............................................................................................................7-84 Counterbalance Valve Test Procedure .....................................................................................7-85 Auxiliary Functions Circuit ..........................................................................................................7-86 Auxiliary Functions Circuit ........................................................................................................7-86 4WE6 - Aux. Functions and Mast Valves ....................................................................................7-88 Repair Kits ................................................................................................................................7-90 Exploded View of 4WE6 ...........................................................................................................7-91 Hydraulic Operated Breakout Wrench ........................................................................................7-92 Setting of HOBO Sequence Valves ..........................................................................................7-93 Hydraulic Systems ........................................................................................................................7-94 Pipe Safety Arm........................................................................................................................7-95 Hydraulic Gear Pumps - Removal and Relpacement...............................................................7-96 Hydraulic Gear Pumps - Repair ...............................................................................................7-96 Hydraulic Gear Pumps - Shaft Seal Removal and Replacement .............................................7-97 Cooler Fan Circuit .........................................................................................................................7-99 Fan Motor Circuit ......................................................................................................................7-99 Cooler Fan Motor ........................................................................................................................7-102 BI620424

xii SKSS Introduction Contents Hydraulic Motor ......................................................................................................................7-102 Hydraulic Thermostatic Valve ....................................................................................................7-106 Hydraulic Cooler - Thermal Valve ...........................................................................................7-106 Central Lube ................................................................................................................................7-107 Hydraulic Circuit .....................................................................................................................7-108 Air Conditioner Compressor Drive Circuit ...............................................................................7-109 Air Conditioner Drive Motor ........................................................................................................7-110 Design .....................................................................................................................................7-110 Operational Check...................................................................................................................7-110 Shaft Seal Replacement..........................................................................................................7-111 Screw Tightening Torque .........................................................................................................7-111 Gear Backlash .........................................................................................................................7-111 Specifications ..........................................................................................................................7-111 Parts List .................................................................................................................................7-112 Water Injection / Foam Injection Circuit ....................................................................................7-113 Water Injection / Foam Injection Valve ....................................................................................7-114 Water Injection / Foam Injection Valve ......................................................................................7-116 Introduciton..............................................................................................................................7-116 Valve Stack Assembly .............................................................................................................7-117 Segment Alterations ................................................................................................................7-118 Pulsar Solenoid Removal and Plug ........................................................................................7-120 Recommended Test Stand .....................................................................................................7-121 Final Stack Adjustment ...........................................................................................................7-124 Assembly Drawing - VBL Bypass Inlet Segment Parts List ....................................................7-130 Assembly Drawing - VPL Work Segment Parts List ...............................................................7-132 Water Pump Motor ......................................................................................................................7-134 Water Pump Motor Repair Information ...................................................................................7-134 Shaft Seal Repair ...................................................................................................................7-135 Foam Injection Unit.....................................................................................................................7-138 Hydraulic Cylinder Repair ..........................................................................................................7-139 General Information................................................................................................................7-140 H Head ...................................................................................................................................7-142 N Head ...................................................................................................................................7-143 Z Head ....................................................................................................................................7-144 Z Head ( Two Piece) ...............................................................................................................7-145 K Head ...................................................................................................................................7-146 M Head ...................................................................................................................................7-147 Z Piston ..................................................................................................................................7-148 Z Piston (Threaded) ...............................................................................................................7-149 H & K Piston ...........................................................................................................................7-150 M Piston .................................................................................................................................7-151 N Piston ..................................................................................................................................7-154 Section 8 - Electrical Components .................................................8-1 Section 8 Contents .........................................................................................................................8-3 Electrical Locator ............................................................................................................................8-4 BI620424

SKSS Introduction xiii Contents Electrical Locator Parts List ........................................................................................................8-6 Jump Starting ..................................................................................................................................8-7 Batteries ..........................................................................................................................................8-9 Welding Precautions ....................................................................................................................8-10 Vigilante Guide ...............................................................................................................................8-11 Important Information ................................................................................................................8-11 PLC ..........................................................................................................................................8-12 EEPROM ..................................................................................................................................8-13 Output Card ..............................................................................................................................8-14 Touchscreen .............................................................................................................................8-15 Laser Depth System .................................................................................................................8-16 Safety Instructions & Precautions ............................................................................................8-17 Pipe in Hole Detection ..............................................................................................................8-18 Distance Meter .........................................................................................................................8-18 Start Up and Shut Down...........................................................................................................8-19 Hydraulic Function Enable .......................................................................................................8-19 Alarms ......................................................................................................................................8-19 Solenoid Control .......................................................................................................................8-20 Auto Lube .................................................................................................................................8-23 Hammer Oiler System ..............................................................................................................8-23 Gauges .....................................................................................................................................8-24 Pressure Transducer ................................................................................................................8-24 Level Transducer ......................................................................................................................8-24 Hammer Oil Level Transducer..................................................................................................8-24 Temperature Transducer ..........................................................................................................8-25 Water Flow Transducer ............................................................................................................8-27 Inclinometers ............................................................................................................................8-28 Head Speed Module.................................................................................................................8-29 Level Switches .........................................................................................................................8-30 Dust Suppression .....................................................................................................................8-30 Turkey Spray ............................................................................................................................8-30 Water Suppression Tank - Top Up ............................................................................................8-30 Vigilante System Component Information .................................................................................8-31 Head Speed Module.................................................................................................................8-31 Rotary Head Speed Flowmeter ................................................................................................8-33 Inclinometer ..............................................................................................................................8-37 Ladder Prox Switch ..................................................................................................................8-40 LDM 40 A Laser ........................................................................................................................8-41 Level Switches - Capacitive Level Switch (Hydraulic Oil Level) ...............................................8-53 Radiator Level Switch...............................................................................................................8-57 Level Transducer - Electronic Level Sensor .............................................................................8-61 Hammer Oil Level Transducer..................................................................................................8-71 Pressure Transducer - Combined Pressure Sensor.................................................................8-73 Temperature Transducer - Control Monitor for Temperature Sensors ......................................8-82 Temperature Sensor .................................................................................................................8-94 Water Flow Transducer - Flow Sensor Analog .........................................................................8-95 BI620424

xiv SKSS Introduction Contents Water Control Module.............................................................................................................8-109 Rod Counter Switch ...............................................................................................................8-138 Remote Fuel Level Display ....................................................................................................8-139 Section 9 - Lubrication and Preventive Maintenance ...................9-1 Section 9 Contents .........................................................................................................................9-3 Central Lube System ......................................................................................................................9-5 Hydraulic Control Schematic ......................................................................................................9-6 Auto Lube ...................................................................................................................................9-6 Central Lube Pump Module......................................................................................................9-10 Central Lube Pump ..................................................................................................................9-23 Hammer Oiler Tank Assembly .....................................................................................................9-49 Hammer Oil Circuit .......................................................................................................................9-50 Hammer Oil System ......................................................................................................................9-51 Air Service Unit Components ...................................................................................................9-51 Filter Regulator .........................................................................................................................9-52 Air Line Oiler .............................................................................................................................9-53 Fire Ball 425 Pump - Instructions .............................................................................................9-54 Pipe Thread Lubricator ................................................................................................................9-71 Air Service Unit .........................................................................................................................9-71 Filter Regulator .........................................................................................................................9-72 Air Line Lubricator ....................................................................................................................9-73 Pipe Thread Pump ...................................................................................................................9-74 Filter Locator .................................................................................................................................9-82 Lubrication General ......................................................................................................................9-84 Equipment Lubrication..............................................................................................................9-84 Care of Lubrication Points ........................................................................................................9-84 Torque Valves for Split Flange Connections..............................................................................9-85 Lubrication and Preventive Maintenance ...................................................................................9-88 Safety .......................................................................................................................................9-88 Track Gear................................................................................................................................9-88 Engine Maintenance.................................................................................................................9-90 Air Cleaners ..............................................................................................................................9-91 Air Filter Elements ....................................................................................................................9-91 Alternator Maintenance ............................................................................................................9-91 Pump Drive and Drive Shaft Maintenance ...............................................................................9-92 Compressor Maintenance ........................................................................................................9-92 Cooler Packs ............................................................................................................................9-92 A-Frame and Pivot Point Maintenance.....................................................................................9-94 Pull Down and Hoist Ropes and Sheaves Maintenance ..........................................................9-94 Hydraulic System Maintenance ................................................................................................9-96 Hydraulic Maintenance .............................................................................................................9-96 Water Pump Maintenance ........................................................................................................9-96 Cab Maintenance .....................................................................................................................9-96 Air Conditioner Maintenance ....................................................................................................9-98 Battery Maintenance ................................................................................................................9-98 BI620424

SKSS Introduction xv Contents Lubrication System Maintenance .............................................................................................9-98 Fire Suppression Maintenance.................................................................................................9-98 Lubrication and Maintenance Chart 250hr ...............................................................................9-100 Lubrication and Maintenance Chart 500hr ................................................................................9-110 Lubrication and Maintenance Chart 1000hr .............................................................................9-121 Lubrication and Maintenance Chart 2000hr .............................................................................9-132 Lubricant Specifications ............................................................................................................9-144 Hydraulic System ...................................................................................................................9-144 Hydraulic Tank Capacity .........................................................................................................9-144 Compressor Lubrication .........................................................................................................9-145 Compressor Lubricant Specifications .....................................................................................9-145 Lubricating Grease .................................................................................................................9-146 Gear Lubricant........................................................................................................................9-146 Scheduled Oil Sampling Analysis ...........................................................................................9-146 BI620424

xvi SKSS Introduction General Locator BI620424

SKSS Introduction xvii General Locator BI620424

xviii SKSS Introduction General Locator BI620424

Section 1 Safety

CAUTION: DO NOT weld on any part of the machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. On machines equipped with electronic engine, disconnect the connections to the Electronic Control Module (ECM) on the engine before welding (see Section 8).

Safety SKSS Safety 1-1

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SKSS Safety 1-3 Section 1 - Safety.............................................................................. 1-1 Section 1 Contents .........................................................................................................................1-3 Safety ...............................................................................................................................................1-4 Personal Protective Equipment ..................................................................................................1-4 Noise ..........................................................................................................................................1-4 Electrical Contact .......................................................................................................................1-4 Overhead and Buried Utilities.....................................................................................................1-4 Contact with Electric Wires .........................................................................................................1-5 Contaminated Air ........................................................................................................................1-5 Machine Stability ........................................................................................................................1-6 Moving and Rotating Parts .........................................................................................................1-7 High Pressure Air or Fluid ..........................................................................................................1-7 Before Operation ........................................................................................................................1-7 During Operation ........................................................................................................................1-8 Maintenance .............................................................................................................................1-10 Safety Locator ...........................................................................................................................1-11 Section 1 Contents BI620424

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

• and drilling assignment sheets.

Should be located, noted and emphasised on all drilling location plans

• project, consider all wires to be live and dangerous.

Whenever overhead power lines exist on or near a drilling site or

• lines to gain entrance.

Watch for sagging power lines before entering a site. Do not lift power

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.

• line or underground utility without a permit indicating “danger zones” and minimum clearances.

Do not raise the mast or operate the drill rig within a minimum of 10 meters of any electrical power

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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

• Follow site emergency procedures •

Do not attempt to leave the machine

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

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

Contaminated Air

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

DANGER: Contaminated air will cause severe injury or death

SKSS Safety 1-5 Safety

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Machine Stability

• potentially collapse or subside.

•

The machine should never be propelled over areas that could

Visual inspections of the path to be taken must be made

All precautions relating to underground workings must be adhered to

• water

Never tram through areas of soft unconsolidated materials holding

• Do not tram the machine with the tower raised over rough or

If propelling on inclines is required, never travel across grades

• 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.

1-6 SKSS Safety

Safety

9.90 = 17.5% 15.80 = 28% 180 = 32.5% 25.20 = 47% 7.70 = 14% 13.50 = 24%

TOTAL WEIGHT, FULLY LADEN 98 TONNES

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

Moving and Rotating Parts

• clear of the area.

The machine should not be operated unless all people are well

• should be activated with another person on the deck or in the vicinity of the machine unless clear communication methods have been established

•

The drill is designed for single person operation and no control

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

• Wear all mandatory (ie safety helmet, eye protection, hearing protection) and other necessary

Study and fully understand this manual.

• Personal Protective Equipment when operating or working on or in the vicinity of the machine.

• condition.

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

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 1-7 Safety

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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.

1-8 SKSS Safety Safety

Dust Curtain Raised Emergency Stop

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Auto Pulldown Off

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

•

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.

• secure footing.

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

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 propel the machine with the mast up.

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

•

SKSS Safety 1-9 Safety

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

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CAT Bucyrus Terex SKSS-15 Infinity Blasthole Drill Service Manual SN1K67X13 – PDF DOWNLOAD

Technical Manual

Parts Ordering and Product Support

Parts Ordering and Product Support

1. IDENTIFICATION OF THE MACHINE

3. SHIPMENT

Section 1 Safety

Personal Protective Equipment

Noise

Electrical Contact

Overhead and Buried Utilities

Contact With Electric Wires

Contaminated Air

Machine Stability

Moving and Rotating Parts

High Pressure Air or Fluid

Before Operation

During Operation