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Cat Bucyrus SCH5000 Hydra-Trac Hydraulic Track Drill Service Manual SN 411310 – PDF DOWNLOAD
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Cat Bucyrus SCH5000 Hydra-Trac Hydraulic Track Drill Service Manual SN 411310 – PDF DOWNLOAD
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Description
Cat Bucyrus SCH5000 Hydra-Trac Hydraulic Track Drill Service Manual SN 411310 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus SCH5000 Hydra-Trac Hydraulic Track Drill Service Manual SN 411310 – PDF DOWNLOAD
Language : English
Pages : 767
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Cat Bucyrus SCH5000 Hydra-Trac Hydraulic Track Drill Service Manual SN 411310 – PDF DOWNLOAD
Safety Instructions:
Before Operation:
• Do notify the owner of overhead or underground power lines before drilling. Be sure to comply
with all local regulations regarding safe operating distances from power lines. See table 1-1 for
general guidelines for safe distances from high voltage lines.
• Do study this manual and fully understand the controls.
• Do be sure all safety guards are securely in place.
• Do wear safety helmet, glasses and hearing protection when operating or working on machine.
• Do be sure all personnel are clear of the machine and work area before starting the engine or
operating machine.
• Do be sure drill area is clear of all obstructions before operating machine.
• Do attach safety chain when using towbar.
• Do Not operate machine with:
• Hydraulic or air leaks
• Broken or damaged electrical wiring or components
• Damaged hydraulic hoses or fittings
Operation:
• Do examine the surface before drilling to determine the possible presence of unfired explosives.
• Do provide sufficient ventilation when running the engine in an enclosed area. Exhaust gasses
contain carbon monoxide, a deadly poison, which is colorless and odorless.
• Do keep work areas clean and clear of cuttings, hand tools and other objects.
• Do place feed in horizontal position with feed resting on feed rest (if equipped) when tramming
over rough ground or during long moves. When moving from hole to hole, be sure feed is high
enough to clear ground obstacles. If feed hits something while tramming, feed can fall causing
serious injury or death.
• Do Not use the machine for any other purpose than what it was designed for. This machine is
designed for blasthole drilling operations only.
• Do Not wear jewelry or loose fitting clothing when working on machinery. Keep clothing and
hands clear of moving parts.
• Do Not travel on steep inclines, soft or unstable ground or close to unsupported excavations.
• Do Not move boom or machine if it is in a potentially unstable position.
• Do Not stand directly under a boom or feed.
• Do Not drill into or near a “bootleg” hole or any hole that may contain explosives.
After Operation:
• Follow Shut Down Procedures as listed in Operator’s Manual.
• Do examine the surface before drilling to determine the possible presence of unfired explosives.
• Do provide sufficient ventilation when running the engine in an enclosed area. Exhaust gasses
contain carbon monoxide, a deadly poison, which is colorless and odorless.
• Do keep work areas clean and clear of cuttings, hand tools and other objects.
• Do place feed in horizontal position with feed resting on feed rest (if equipped) when tramming
over rough ground or during long moves. When moving from hole to hole, be sure feed is high
enough to clear ground obstacles. If feed hits something while tramming, feed can fall causing
serious injury or death.
• Do Not use the machine for any other purpose than what it was designed for. This machine is
designed for blasthole drilling operations only.
• Do Not wear jewelry or loose fitting clothing when working on machinery. Keep clothing and
hands clear of moving parts.
• Do Not travel on steep inclines, soft or unstable ground or close to unsupported excavations.
• Do Not move boom or machine if it is in a potentially unstable position.
• Do Not stand directly under a boom or feed.
• Do Not drill into or near a “bootleg” hole or any hole that may contain explosives.
After Operation:
• Follow Shut Down Procedures as listed in Operator’s Manual.
Maintenance:
• Do have two people present when performing service work, both being fully trained on the safety
issues. One person shall supervise from the operator’s position and have immediate access to an
emergency stop in all situations. Visual, audible or verbal communication signals must be established
and understood by both persons.
• Do make sure each person is adequately trained to perform service and maintenance procedures.
• Do place a warning tag on starting controls to alert personnel that someone is working on the
machine and disconnect battery before making repairs or adjustments to machine.
• Do have adequate lighting when performing service work at night.
• Do relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.
• Do make sure machine and components are well supported before servicing or replacing parts.
• Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel
tank. This will prevent sparks and the possibility of an explosion.
• Do make sure no tools or other loose objects are left on the engine or drive mechanisms. They
could be thrown by this equipment with a powerful force.
• Do Not service or perform maintenance while machine is running.
• Do Not smoke or use an open flame near batteries, when servicing the batteries. Batteries can
give off hydrogen which is a highly explosive gas.
• Do Not hammer bit or drill steel. Use only proper tools to make repair or adjustments.
• Do Not weld or grind near oil lines.
• Do Not attempt to remove radiator cap when engine is hot or has overheated.
• Do have two people present when performing service work, both being fully trained on the safety
issues. One person shall supervise from the operator’s position and have immediate access to an
emergency stop in all situations. Visual, audible or verbal communication signals must be established
and understood by both persons.
• Do make sure each person is adequately trained to perform service and maintenance procedures.
• Do place a warning tag on starting controls to alert personnel that someone is working on the
machine and disconnect battery before making repairs or adjustments to machine.
• Do have adequate lighting when performing service work at night.
• Do relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.
• Do make sure machine and components are well supported before servicing or replacing parts.
• Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel
tank. This will prevent sparks and the possibility of an explosion.
• Do make sure no tools or other loose objects are left on the engine or drive mechanisms. They
could be thrown by this equipment with a powerful force.
• Do Not service or perform maintenance while machine is running.
• Do Not smoke or use an open flame near batteries, when servicing the batteries. Batteries can
give off hydrogen which is a highly explosive gas.
• Do Not hammer bit or drill steel. Use only proper tools to make repair or adjustments.
• Do Not weld or grind near oil lines.
• Do Not attempt to remove radiator cap when engine is hot or has overheated.
TABLE OF CONTENTS:
Cat Bucyrus SCH5000 Hydra-Trac Hydraulic Track Drill Service Manual SN 411310 – PDF DOWNLOAD
SCH5000Service.pdf...................................................................................................................... 0 Introduction........................................................................................................................ 4 Table of Contents............................................................................................................... 5 U.S./Metric Conversions......................................................................................................... 13 Glossary of Terms............................................................................................................... 15 Component Locations (C-10 engine)............................................................................................... 17 Component Locations (3306 engine)............................................................................................... 21 Section 1........................................................................................................................... 28 SAFETY.............................................................................................................................. 28 Overview of Potential Hazards................................................................................................... 29 Safety Instructions............................................................................................................. 30 Clearances from High Voltage Lines.............................................................................................. 30 Section 2........................................................................................................................... 34 MAIN FRAME/TRACKS (INTERTRACTOR CRAWLERS)........................................................................................... 34 Track Oscillation Cylinders..................................................................................................... 35 Removal..................................................................................................................... 35 Installation................................................................................................................ 35 Track Maintenance............................................................................................................... 36 Track Tension Adjustment........................................................................................................ 37 Metric Bolt Torque Specifications............................................................................................... 39 Track Assembly.................................................................................................................. 40 Separate Track Chain Assembly............................................................................................... 40 Track Link - Repair & Replace............................................................................................... 41 Track Shoe (grouser) - Mounting to Track Chain.............................................................................. 43 Grouser Bolt Torque (Direct Torque Method).................................................................................. 45 Grouser Bolt Torque (Torque Turn Method).................................................................................... 46 Track Chain & Shoe - Assembly & Installation................................................................................ 47 Final Drive - General Description............................................................................................... 49 Removal from Track Frame.................................................................................................... 50 Installation into Track Frame............................................................................................... 51 Final Drive Maintenance..................................................................................................... 52 Oil Check / Change...................................................................................................... 52 Final Drive Oil......................................................................................................... 53 Final Drive Assembly........................................................................................................ 55 Brake Assembly.......................................................................................................... 58 Idler Unit...................................................................................................................... 59 General Description......................................................................................................... 59 Removal and Disassembly..................................................................................................... 61 Assembly and Installation................................................................................................... 63 Track Rollers................................................................................................................... 66 General Description......................................................................................................... 66 Removal & Disassembly....................................................................................................... 67 Track Roller - Assembly..................................................................................................... 69 Track Roller - Test and Install............................................................................................. 70 Support Rollers................................................................................................................. 71 General Description......................................................................................................... 71 Removal & Disassembly....................................................................................................... 72 Reedrill Crawlers (early machines).................................................................................................. 74 Track Oscillation Cylinders..................................................................................................... 75 Removal..................................................................................................................... 75 Installation................................................................................................................ 75 Track Tension Adjustment........................................................................................................ 76 Track Assembly.................................................................................................................. 78 Separate Track Chain Assembly............................................................................................... 78 Connect Track Assemblies.................................................................................................... 80 Front Idler & Recoil Spring..................................................................................................... 82 Removal..................................................................................................................... 82 Replace..................................................................................................................... 83 Front Idler Disassembly..................................................................................................... 84 Front Idler Assembly........................................................................................................ 86 Track Carrier Rollers........................................................................................................... 88 Removal..................................................................................................................... 88 Replace..................................................................................................................... 89 Duo-Cone Seals.............................................................................................................. 90 Final Drive Oil................................................................................................................. 94 Checking Oil Level in Final Drive........................................................................................... 95 Changing Oil in Final Drive................................................................................................. 95 Towing Procedure (late models).............................................................................................. 97 Gear Drive Disconnect (machines with spacer)................................................................................ 97 Gear Drive Disconnect (early model machines with spring).................................................................... 99 Final Drive Disengage Spacer Retrofit.......................................................................................101 Final Drive Assembly........................................................................................................103 Final Drive Repair......................................................................................................107 Final Drive Motors......................................................................................................108 Section 3...........................................................................................................................112 POWER TRAIN.........................................................................................................................112 Hydraulic Pumps.................................................................................................................113 Removal and Installation....................................................................................................113 Pump Drive......................................................................................................................114 Funk Pump Drive - Removal (for machines built after May, 1998)..............................................................114 Funk Pump Drive Gearbox - Repair............................................................................................115 Terrell Pump Drive Gearbox - Repair.........................................................................................119 Hydraulic Pump Retrofit Procedure...............................................................................................124 Rexroth Pump Installation...................................................................................................125 Fuel System - Cat 3306 Engine...................................................................................................133 Fuel Tank Maintenance.......................................................................................................133 Fuel Filters - Every 250 Hours of Operation.................................................................................134 Priming the Fuel System.....................................................................................................134 Fuel System - Cat C-10 Engine...................................................................................................135 Fuel Tank Maintenance.......................................................................................................135 Fuel Filters - Every 250 Hours of Operation.................................................................................136 Priming the Fuel System.....................................................................................................136 Coolers - 3306 Engine...........................................................................................................137 Engine Radiator - Capacity and Service......................................................................................137 Coolant Specifications......................................................................................................138 Coolers - Removal and Installation..........................................................................................141 Coolers - C-10 Engine...........................................................................................................139 Engine Radiator - Capacity and Service......................................................................................139 Coolant Specifications......................................................................................................140 Coolers - Removal and Installation..........................................................................................143 Section 4...........................................................................................................................146 HYDRAULIC/ELECTRICAL SYSTEMS/CAB COMPONENTS.........................................................................................146 Hydraulic System................................................................................................................147 Basic Hydraulic Schematic (Vickers Pump)........................................................................................148 Basic Hydraulic Schematic (Rexroth Pumps).......................................................................................149 Tram Console with Boom Hosing...................................................................................................150 Hydraulic Schematic - Drill Console.............................................................................................151 Hydraulic Schematic - Cab.......................................................................................................152 Rod Changer Piping..............................................................................................................154 Boom Piping.....................................................................................................................155 Hydraulic Valves - Maintenance..................................................................................................156 Boom/Feed Pilot Valve.......................................................................................................156 Tram Pilot Valve............................................................................................................157 Electrical Arrangement - 3306 Engine............................................................................................158 D.C. Schematic - Non-Cab (3306 Engine)..........................................................................................161 D.C. Schematic - with Cab (3306 Engine).........................................................................................163 Wiring Diagram - with Cab (3306 Engine).........................................................................................169 Wire Number/Color Code Chart (3306 Engine)......................................................................................172 Wiring Diagram - Boom Control Panel.............................................................................................175 Wiring Diagram - Drill Control Panel............................................................................................176 Wiring Diagram - Tram Control Panel.............................................................................................177 Wiring Diagram - Instrument Panel (3306 Engine).................................................................................178 Air Ride Seat Assembly..........................................................................................................179 Electrical Arrangement - C-10 Engine............................................................................................184 D.C. Schematic with Cab (C-10 Engine)...........................................................................................187 Wiring Diagram - Instrument Panel (C-10 Engine).................................................................................192 Wiring Diagram with Cab (C-10 Engine)...........................................................................................193 Section 5...........................................................................................................................195 AIR SYSTEM..........................................................................................................................195 Air Receiver Tank...............................................................................................................196 Preventive Maintenance......................................................................................................196 Troubleshooting.............................................................................................................198 Air System Components...........................................................................................................200 Compressor Oil Piping...........................................................................................................201 Thermostatic Bypass Valve...................................................................................................201 Air Valve Piping (cab machines).................................................................................................202 Air Valve Piping (non-cab machines).............................................................................................203 Compressor Assembly.............................................................................................................204 Compressor Unit.............................................................................................................205 Drive Coupling - Replacement................................................................................................205 Air Compressor Drive Motor..................................................................................................206 Variable Displacement Motor Adjustment..................................................................................207 Detergent Tank Piping...........................................................................................................208 Section 6...........................................................................................................................209 Boom & Feed Components..............................................................................................................209 Boom Lift Cylinder..............................................................................................................210 Removal.....................................................................................................................210 Replace.....................................................................................................................211 Cylinder Bleeding Procedure and Final Installation:.........................................................................211 Boom Swing Cylinder.............................................................................................................212 Removal.....................................................................................................................212 Replace.....................................................................................................................213 Cylinder Bleeding Procedure and Final Installation:.........................................................................213 Feed Dump Cylinder..............................................................................................................214 Removal.....................................................................................................................214 Replace.....................................................................................................................215 Cylinder Bleeding Procedure and Final Installation:.........................................................................215 Feed Swing Cylinder.............................................................................................................216 Removal.....................................................................................................................217 Replace.....................................................................................................................219 Cylinder Bleeding Procedure and Final Installation:.........................................................................219 Indexing the Feed Swing Cylinder............................................................................................220 Feed Extension Cylinder.........................................................................................................223 Removal.....................................................................................................................223 Replace.....................................................................................................................225 Cylinder Bleeding Procedure and Final Installation:.........................................................................225 Boom Shim/Wear Pad Replacement..................................................................................................226 Boom Wear Pads - Inspection.................................................................................................227 Feed and Feed Table - Removal from Boom.....................................................................................228 Inner Boom Tube - Removal...................................................................................................231 Rear Wear Pads and Shims - Installation.....................................................................................233 Front Wear Pads and Shims - Installation....................................................................................235 Feed and Feed Table - Installation on Boom..................................................................................236 Boom Wear Pads - Final Inspection...........................................................................................239 HPR2 Hydraulic Rock Drill.......................................................................................................240 Removal from Feed...........................................................................................................241 Mounting Slide Adjustment...................................................................................................242 Feed Chain Adjustment...........................................................................................................243 Traveling Hose Reel Timing......................................................................................................244 Feed Table Wear Pad Adjustment..................................................................................................246 Feed Table Pivot Pin............................................................................................................247 Adjustment and Maintenance..................................................................................................247 Section 7...........................................................................................................................249 PRESSURE SETTINGS & ADJUSTMENTS.....................................................................................................249 Engine Adjustments - Caterpillar 3306...........................................................................................250 Engine Adjustments - Cat C-10...................................................................................................252 Brake Valve Adjustments.........................................................................................................254 Tram System.....................................................................................................................258 Feed/Boom Valve Adjustment......................................................................................................269 Main Pump Adjustments (Vickers PVD45)...........................................................................................270 Main Pump Adjustments (Rexroth A11VLO)..........................................................................................274 Rotation Pump Circuit...........................................................................................................278 Drill & Feed Valve Adjustments..................................................................................................282 Collaring Circuit Adjustment....................................................................................................284 Anti-Jam / Collaring Circuit....................................................................................................286 Reverse Percussion Option.......................................................................................................289 Dust Collector Assembly.........................................................................................................294 Function of Dust Collector..................................................................................................295 Initial Start-up and Tuning.................................................................................................296 Dust Collector Valve - Adjustment...........................................................................................296 Air Pressure Regulator - Adjustment.........................................................................................297 Timer - Adjustment..........................................................................................................298 Filter Elements.............................................................................................................300 Operational Variables.......................................................................................................301 Fine Tuning.................................................................................................................301 Manometer Setup Instructions................................................................................................303 Timer Installation..........................................................................................................304 Control Circuit.............................................................................................................305 Fan Removal and Installation................................................................................................306 Troubleshooting Hints.......................................................................................................307 Centralizer Adjustment..........................................................................................................309 Vertical Indicator..............................................................................................................310 Rod Changer Valve...............................................................................................................312 Pressure Adjustments........................................................................................................312 3 Bank Valve - Cab/Drill Console................................................................................................314 Pressure Adjustments........................................................................................................314 Coupling Grease System..........................................................................................................316 Adjustments.................................................................................................................317 Daily Maintenance...........................................................................................................317 Air Pressure Regulator......................................................................................................318 Filter Assembly.............................................................................................................319 Lubricator Assembly.........................................................................................................320 3-Way Air Valve.............................................................................................................322 Section 8...........................................................................................................................327 VENDOR SERVICE INFORMATION..........................................................................................................328 Bonfiglioli.....................................................................................................................331 Char-Lynn / H Series............................................................................................................363 Char-Lynn 2000 Series...........................................................................................................371 Fairfield / CT26C...............................................................................................................381 Fairfield S1A Final Drive.......................................................................................................423 General Engineering.............................................................................................................436 Lincoln / 82716 - Series "F"....................................................................................................439 Rexroth / A2FM90................................................................................................................449 Rexroth / A6VM107...............................................................................................................469 Rexroth / A11VLO130.............................................................................................................497 Rexroth / A4FM28................................................................................................................545 Star Dynamics...................................................................................................................548 Sundstrand/Series 51............................................................................................................551 Texas Hydraulics................................................................................................................570 Vickers / PVE19L................................................................................................................587 Section 9...........................................................................................................................619 Hydraulic Rock Drill Repair.........................................................................................................619 HPR2 Service 408860.pdf.............................................................................................................620 Table of Contents...............................................................................................................623 Overview of Potential Hazards...................................................................................................629 Safety Instructions.............................................................................................................630 Maintenance and Equipment Transfer..............................................................................................632 Start-Up Procedure..............................................................................................................635 Operation and After Operation...................................................................................................631 General Maintenance Tips........................................................................................................636 Preventive Maintenance..........................................................................................................637 At the beginning of every shift:................................................................................................638 TROUBLESHOOTING.................................................................................................................641 General Tips on Drill Overhaul..................................................................................................649 Tool Requirements...............................................................................................................650 Special Tool List...............................................................................................................652 Drill Torque Specifications.....................................................................................................656 Removal of Drill from the Feed..................................................................................................658 Installation of Drill on the Feed...............................................................................................660 Drill Disassembly...............................................................................................................661 Drill Assembly..................................................................................................................685 Charging the Accumulators.......................................................................................................729 Hydraulic Oils for Percussion Drills............................................................................................735 Hydraulic Drill Rotation Unit Lubrication.......................................................................................736 HPR2 Wear Tolerances (51mm shank)...............................................................................................737 HPR2 Wear Tolerances (68mm shank)...............................................................................................743 Section 10......................................................................................................................754 LUBRICATION & TORQUE SPECIFICATIONS.............................................................................................754 Hydraulic Oils for Percussion Drills........................................................................................755 Lubrication and Inspection..................................................................................................756 Engine Oil..................................................................................................................756 Preventive Maintenance Chart................................................................................................757 Bolt Maintenance............................................................................................................759 Bolt Torque Specifications..................................................................................................760 Maintenance Record..........................................................................................................761
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