Cat Rotary Track Drill MD6290 SKF-98 Infinity Blasthole Drill Service Manual – PDF DOWNLOAD

Description

Cat Rotary Track Drill MD6290 SKF-98 Infinity Blasthole Drill Service Manual – PDF DOWNLOAD

DESCRIPTION:

Cat Rotary Track Drill MD6290 SKF-98 Infinity Blasthole Drill Service Manual – PDF DOWNLOAD

This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury or property damage.

WARNING: BEFORE starting engine:
• Study Operator and Service Manuals
• Study Engine Operator and Maintenance Manual
• Practice All Safety Precautions
• Make Pre-operation Check
• Learn Controls Before Operating

WARNING:

DO NOT use this machine for any other purpose than blasthole drilling. The Infinity Series rotary blasthole drill is designed for blasthole drilling purposes only. Any other use could result in personal injury and/or property damage and will void the warranty.

CAUTION:

Each person performing service work must be satisfied that they have adequate knowledge and training to perform the required tasks. A thorough understanding of hydraulic and pneumatic systems as well as electrical and mechanical knowledge and experience is required.

• This manual is furnished with your Infinity Series rotary blasthole drill to aid you in performing the necessary service work to maintain your drill in good operating condition. This manual contains repair and adjustment information for all major operating systems on the machine.
• In some cases such as hydraulic pumps and motors it is better to replace the unit with a new or rebuilt unit than to perform major repairs. Should further information be desired or should particular problems arise which are not covered sufficiently in this manual, the matter should be referred to manufacturer

The descriptions and specifications contained in this manual were in effect at the time of printing. The right is reserved to make changes at any time without notice and without obligation.

• It is YOUR responsibility to understand and follow manufacturer’s instructions on machine operation and service, and to observe pertinent safety precautions, laws and regulations.
• Failure to read and understand this manual and all safety, capacity and instruction placards on the machine before operating the unit, constitutes a misuse of the machine. It is your responsibility to know the manufacturer’s specific requirements, government regulations, required precautions and any work hazards which may exist.
• You must make these known to all personnel working with the equipment or in the area, so that all may take the necessary and required safety precautions. Keep all children, visitors, and untrained personnel away from the equipment.
• It is also your responsibility to operate your equipment with skill, good judgment, and caution. Following recognised safety procedures will help you avoid accidents. Failure to heed these instructions can result in property damage, serious injury or death.

TABLE OF CONTENTS:

Cat Rotary Track Drill MD6290 SKF-98 Infinity Blasthole Drill Service Manual – PDF DOWNLOADSection 1 Contents………………………………………………………………………………………………………….. 1-3
Safety……………………………………………………………………………………………………………………………… 1-5
Personal Protective Equipment……………………………………………………………………………………… 1-5
Noise…………………………………………………………………………………………………………………………. 1-5
Electrical Contact………………………………………………………………………………………………………… 1-5
Contaminated Air…………………………………………………………………………………………………………. 1-6
Moving and Rotating Parts……………………………………………………………………………………………. 1-7
High Pressure Air or Fluid…………………………………………………………………………………………….. 1-7
Before Operation…………………………………………………………………………………………………………. 1-7
During Operation…………………………………………………………………………………………………………. 1-8
Maintenance……………………………………………………………………………………………………………… 1-10
Safety Locator…………………………………………………………………………………………………………….1-11
Notes…………………………………………………………………………………………………………………………….. 1-14
Section 2 – Operator’s Cab / Controls……………………………………… 2-1
Section 2 Contents………………………………………………………………………………………………………….. 2-3
Graphic Symbol Legend………………………………………………………………………………………………….. 2-5
Graphic Symbol Legend……………………………………………………………………………………………….. 2-5
Warning Decals……………………………………………………………………………………………………………….. 2-9
Warning Decals…………………………………………………………………………………………………………… 2-9
Operator Control and Instrument Panels………………………………………………………………………… 2-12
Control Panels…………………………………………………………………………………………………………… 2-12
Right Hand Control Panel……………………………………………………………………………………………. 2-12
Instrument Panel……………………………………………………………………………………………………….. 2-14
Circuit Breakers…………………………………………………………………………………………………………. 2-15
Light Switches…………………………………………………………………………………………………………… 2-15
System Pressure Gauge Panel……………………………………………………………………………………. 2-16
Left Hand Control Panels……………………………………………………………………………………………. 2-18
Cab Foot Controls……………………………………………………………………………………………………… 2-22
Thread Grease Switch………………………………………………………………………………………………… 2-22
Pipe Safety Arm Override Switch…………………………………………………………………………………. 2-22
Machine Stability…………………………………………………………………………………………………………… 2-23
Tramming Procedure for SK Series Drills……………………………………………………………………… 2-23
Track Adjustments……………………………………………………………………………………………………… 2-23
New Machine Procedure…………………………………………………………………………………………….. 2-24
General Maintenance Checks While Tramming……………………………………………………………… 2-24
Roller Locations…………………………………………………………………………………………………………. 2-25
Temperature and Condition Record Chart for Walking…………………………………………………….. 2-26
Propelling the Machine……………………………………………………………………………………………….. 2-27
Stability Limits…………………………………………………………………………………………………………… 2-29
SKF Transient Stability Limits………………………………………………………………………………………. 2-30
Cab Heater…………………………………………………………………………………………………………………….. 2-31
Cab Heater Fault Isolation…………………………………………………………………………………………… 2-31
Air Conditioner………………………………………………………………………………………………………………. 2-32
T7 Series Split System Air Conditioning Manual…………………………………………………………….. 2-32
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Section 1.0 Technical Data and Control Settings……………………………………………………………. 2-33
Section 2.0 Installation and Commissioning…………………………………………………………………… 2-35
Section 3.0 Routine Maintenance Procedures……………………………………………………………….. 2-41
Section 4.0 Fault Diagnosis…………………………………………………………………………………………. 2-42
Section 5.0 Reference Drawings………………………………………………………………………………….. 2-51
Notes…………………………………………………………………………………………………………………………….. 2-56
Section 3 – Main Frame / Crawlers……………………………………………3-1
Section 3 Contents………………………………………………………………………………………………………….. 3-3
Main Frame Repair – General…………………………………………………………………………………………… 3-5
Main Frame Repair………………………………………………………………………………………………………. 3-5
Weld Inspection Schedule……………………………………………………………………………………………….. 3-6
Main Frame………………………………………………………………………………………………………………… 3-6
Levelling Jacks……………………………………………………………………………………………………………….. 3-7
Levelling Jacks Cylinder……………………………………………………………………………………………….. 3-7
Levelling Jacks……………………………………………………………………………………………………………. 3-8
Limit Switch………………………………………………………………………………………………………………… 3-8
Levelling Jack Cylinders……………………………………………………………………………………………….. 3-8
Mast Elevating Cylinders…………………………………………………………………………………………………. 3-9
Mast Elevating Cylinders………………………………………………………………………………………………. 3-9
Internal Counterbalance Valve…………………………………………………………………………………….. 3-10
Crawler Assembly………………………………………………………………………………………………………….. 3-12
Crawler Assembly………………………………………………………………………………………………………. 3-12
Parts List………………………………………………………………………………………………………………….. 3-13
Crawler Component Repair…………………………………………………………………………………………. 3-13
Tramming………………………………………………………………………………………………………………………. 3-14
Maintenance checks for Tramming for SK Series Drills………………………………………………….. 3-14
Track Adjustments……………………………………………………………………………………………………… 3-14
New Machine Procedure…………………………………………………………………………………………….. 3-15
General Maintenance Checks While Tramming……………………………………………………………… 3-15
Roller Locations…………………………………………………………………………………………………………. 3-16
Temperature and Condition Record Chart for Walking…………………………………………..3-17
Metric Bolt Torque Specifications…………………………………………………………………………………… 3-18
Metric Bolt Torque Specifications…………………………………………………………………………………. 3-18
Track Tension Adjustment……………………………………………………………………………………………… 3-19
Before Operating the Machine…………………………………………………………………………………….. 3-19
General Maintenance…………………………………………………………………………………………………. 3-19
Track Assembly…………………………………………………………………………………………………………. 3-20
Idler Unit Description………………………………………………………………………………………………….. 3-21
Hydraulic Tensioner……………………………………………………………………………………………………. 3-22
Repair………………………………………………………………………………………………………………………. 3-22
Nitrogen Tensioner…………………………………………………………………………………………………….. 3-23
Nitrogen Tensioner – Filling Instructions……………………………………………………………………….. 3-24
Nitrogen Tensioner – Pressure Check…………………………………………………………………………… 3-25
Nitrogen Tensioner – Pressure Release………………………………………………………………………… 3-25
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Hydraulic Tensioner………………………………………………………………………………………………………. 3-26
Hydraulic Tensioner Assembly…………………………………………………………………………………….. 3-26
Repair………………………………………………………………………………………………………………………. 3-26
Track Chain…………………………………………………………………………………………………………………… 3-27
Track Chain – Separate……………………………………………………………………………………………… 3-27
Track Chain Repair……………………………………………………………………………………………………. 3-28
Track Shoes Installation…………………………………………………………………………………………………. 3-30
Track Link Position…………………………………………………………………………………………………….. 3-30
Track Shoe – Mounting to Track Chain…………………………………………………………………………. 3-30
Track Shoe Bolt Torque (Direct Torque Method)……………………………………………………………… 3-32
Bolt Torque KN111……………………………………………………………………………………………………… 3-32
Track Shoe Bolt Torque (Torque Turn Method)……………………………………………………………….. 3-33
Bolt Torque KN111……………………………………………………………………………………………………… 3-33
Track Chain and Shoe Installation………………………………………………………………………………….. 3-34
Track Chain with Shoes……………………………………………………………………………………………… 3-34
Track Chain and Shoe – Assembly and Installation………………………………………………………… 3-34
Final Drive Unit……………………………………………………………………………………………………………… 3-36
General Description……………………………………………………………………………………………………. 3-36
Removal from Track Frame…………………………………………………………………………………………. 3-37
Installation into Track Frame……………………………………………………………………………………….. 3-38
Final Drive Maintenance……………………………………………………………………………………………… 3-39
Final Drive Oil……………………………………………………………………………………………………………. 3-40
Final Drive Assembly………………………………………………………………………………………………….. 3-42
Parking Brake – Description………………………………………………………………………………………… 3-43
Final Drive – Disconnect and Parking Brake………………………………………………………………….. 3-44
Towing Procedure – Gear Drive Disconnect………………………………………………………………….. 3-44
Parking Brake – Description………………………………………………………………………………………… 3-45
Parking Brake – Removal and Installation…………………………………………………………………….. 3-45
Repair Manual Final Drive Model F100 – General Information…………………………………………. 3-46
Repair Manual Final Drive Model F100 – Safety Instructions…………………………………………… 3-51
Repair Manual Final Drive Model F100 – General Specifications……………………………………… 3-55
Disassembly and Assembly Operations………………………………………………………………………… 3-64
Repair Manual Final Drive Model F100 – Troubleshooting………………………………………………. 3-98
Repair Manual Final Drive Model F100 – Special Tools…………………………………………………… 3-99
Idler Unit……………………………………………………………………………………………………………………… 3-100
Idler Unit – Assembly………………………………………………………………………………………………… 3-100
Idler Unit – Removal…………………………………………………………………………………………………. 3-103
Track and Support Rollers……………………………………………………………………………………………. 3-105
Track Roller Assembly………………………………………………………………………………………………. 3-105
Track Roller – Removal and Disassembly…………………………………………………………………… 3-106
Support Roller – Removal and Disassembly………………………………………………………………… 3-106
Track and Support Roller – Assembly…………………………………………………………………………. 3-107
Track and Support Roller – Test and Install………………………………………………………………….. 3-108
Track and Sprocket Inspection……………………………………………………………………………………….3-110
Track Inspection and Wear Limit Guide………………………………………………………………………..3-110
Sprocket Wear Patterns……………………………………………………………………………………………..3-115
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Auxiliary Crane……………………………………………………………………………………………………………. 3-121
Hydraulic Crane – Rear Deck Crane Palfinger PC1300…………………………………………………. 3-121
Rear Deck Crane Palfinger PC1300 Service information………………………………………………. 3-122
Checking Bolted Connections……………………………………………………………………………………. 3-122
Maintenance Chart…………………………………………………………………………………………………… 3-123
Lubrication………………………………………………………………………………………………………………. 3-125
Hydraulic Fluids……………………………………………………………………………………………………….. 3-128
Oil Change / Oil Maintenance……………………………………………………………………………………. 3-129
Cleaning Agents and Equipment………………………………………………………………………………… 3-130
Repairing Paint Damage…………………………………………………………………………………………… 3-131
Removal From Service and Disposal………………………………………………………………………….. 3-131
Notes…………………………………………………………………………………………………………………………… 3-132
Section 4 – Engine / Drive Train / Compressor………………………….4-1
Section 4 Contents………………………………………………………………………………………………………….. 4-3
Power Group Locator………………………………………………………………………………………………………. 4-5
Power Group Locator…………………………………………………………………………………………………… 4-5
Test Point Locator…………………………………………………………………………………………………………… 4-6
Test Point Locator………………………………………………………………………………………………………… 4-6
Cummins Engine…………………………………………………………………………………………………………….. 4-8
Cummins Engine…………………………………………………………………………………………………………. 4-8
Oil Reserve Systems……………………………………………………………………………………………………. 4-9
LED Monitor Readings……………………………………………………………………………………………….. 4-10
Adjustment of Running Oil Level………………………………………………………………………………….. 4-10
Wiring Diagram – Oil Reserve Basic Circuit…………………………………………………………………….4-11
Oil Pressure Switch……………………………………………………………………………………………………..4-11
Oil Reserve System……………………………………………………………………………………………………..4-11
Troubleshooting…………………………………………………………………………………………………………. 4-12
Maintenance……………………………………………………………………………………………………………… 4-13
Engine and Compressor Air Cleaners…………………………………………………………………………….. 4-14
Engine and Compressor Air Cleaner Service Assembly………………………………………………….. 4-14
Engine and Compressor Air Cleaner Service…………………………………………………………………. 4-15
Flexible Drive Coupling………………………………………………………………………………………………….. 4-18
Flexible Drive Coupling Service…………………………………………………………………………………… 4-18
Pump Drive……………………………………………………………………………………………………………………. 4-20
Pump Drive Assembly – Removal and Replacement………………………………………………………. 4-20
Pump Drive Gearbox………………………………………………………………………………………………….. 4-21
Pump Drive Gearbox Repair……………………………………………………………………………………….. 4-21
Hydraulic Pumps…………………………………………………………………………………………………………… 4-23
Hydraulic Pumps……………………………………………………………………………………………………….. 4-23
Hydraulic Pumps – Removal and Replacement……………………………………………………………… 4-25
Compressor Installation…………………………………………………………………………………………………. 4-26
1700cfm / 100psi Compressor…………………………………………………………………………………….. 4-26
Safety………………………………………………………………………………………………………………………. 4-27
Compressor Installation………………………………………………………………………………………………. 4-30
Compressor Drive Coupling………………………………………………………………………………………… 4-31
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Compressor Alignment……………………………………………………………………………………………….. 4-32
Mounting Instructions for Arcusaflex™ Flywheel Couplings……………………………………………… 4-33
Taper-Loc Bushing Installation – Model AC-T5.SN. F2. V1. 3535……………………………………… 4-34
Tightening Torques for ARCUSAFLEX™ Flywheel Couplings………………………………………….. 4-34
Compressor Shaft Seal………………………………………………………………………………………………….. 4-35
Compressor Shaft Seal………………………………………………………………………………………………. 4-35
Low Pressure Compressor…………………………………………………………………………………………….. 4-37
Description……………………………………………………………………………………………………………….. 4-37
Compressed Air Functions………………………………………………………………………………………….. 4-37
Compressor Inlet Valve Control System………………………………………………………………………… 4-41
Inlet Valve…………………………………………………………………………………………………………………. 4-42
Compressor Regulation………………………………………………………………………………………………. 4-44
Relieving Regulators………………………………………………………………………………………………….. 4-45
Reducing Regulators………………………………………………………………………………………………….. 4-47
System Blowdown Valve…………………………………………………………………………………………….. 4-49
Running Blowdown Valve……………………………………………………………………………………………. 4-50
Running Blowdown Maintenance…………………………………………………………………………………. 4-51
Compressor Air and Oil Circuits – 1700cfm @ 100psi…………………………………………………….. 4-52
Operation………………………………………………………………………………………………………………….. 4-55
Compressor Air Circuit Parts List…………………………………………………………………………………. 4-57
Compressor Air Circuit Legend……………………………………………………………………………………. 4-57
Compressor Control Set-up Vented Poppet Inlet – Shutdown………………………………………….. 4-58
Compressor Control Set-up Vented Poppet Inlet – Initial Start-up Below 50psi…………………… 4-59
Compressor Control Set-up Vented Poppet Inlet – Intial Start-up Above 50psi…………………… 4-60
Compressor Control Set-up Vented Poppet Inlet – Run Unloaded……………………………………. 4-61
Compressor Control Set-up Vented Poppet Inlet – Drilling………………………………………………. 4-62
Compressor Maintenance………………………………………………………………………………………………. 4-63
General Maintenance…………………………………………………………………………………………………. 4-63
Discharge Check Valve………………………………………………………………………………………………. 4-65
Compressor Receiver Tank Assembly…………………………………………………………………………… 4-66
Separator Elements……………………………………………………………………………………………………. 4-67
Scavenge Line…………………………………………………………………………………………………………… 4-68
Compressor Discharge Temperature Gauge, Switch and Sender…………………………………….. 4-70
Minimum Pressure Valve…………………………………………………………………………………………….. 4-71
Minimum Pressure / Check Valve Maintenance……………………………………………………………… 4-71
Thermal Bypass Valve………………………………………………………………………………………………… 4-72
Thermal Bypass Valve Maintenance…………………………………………………………………………….. 4-73
Compressor Fluid Filter………………………………………………………………………………………………. 4-75
Changing Filter Elements……………………………………………………………………………………………. 4-76
Oil Stop Valve……………………………………………………………………………………………………………. 4-77
Troubleshooting…………………………………………………………………………………………………………. 4-78
Coolers…………………………………………………………………………………………………………………………. 4-80
Hydraulic Oil / Hydraulic Cooler Assembly…………………………………………………………………….. 4-80
Compressor Oil Cooler……………………………………………………………………………………………….. 4-81
Fan Speed………………………………………………………………………………………………………………… 4-81
Engine Cooler / Radiator…………………………………………………………………………………………….. 4-82
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Aluminium Tube Air to Oil Cooler…………………………………………………………………………………… 4-83
Aluminium Tube Air to Oil Cooler – Standard Parts………………………………………………………… 4-83
Removal Replacement……………………………………………………………………………………………….. 4-84
Oil Cooler – Internal Cleaning……………………………………………………………………………………… 4-86
Radiator Cooler……………………………………………………………………………………………………………… 4-88
Typical Radiator Core – Standard Parts………………………………………………………………………… 4-88
Cleaning…………………………………………………………………………………………………………………… 4-89
Tube Removal…………………………………………………………………………………………………………… 4-89
Seal Installation…………………………………………………………………………………………………………. 4-90
Tube Installation………………………………………………………………………………………………………… 4-91
Notes…………………………………………………………………………………………………………………………….. 4-93
Section 5 – Dust Control System………………………………………………5-1
Section 5 Contents………………………………………………………………………………………………………….. 5-3
Dust Control System……………………………………………………………………………………………………….. 5-5
Dust Control Systems…………………………………………………………………………………………………… 5-5
Water Injection………………………………………………………………………………………………………………… 5-7
Basic Specifications…………………………………………………………………………………………………….. 5-7
Technical Data…………………………………………………………………………………………………………….. 5-7
Initial Start-up……………………………………………………………………………………………………………… 5-9
Fan Speed Adjustment…………………………………………………………………………………………………. 5-9
Fan Speed Adjustment…………………………………………………………………………………………………. 5-9
Direction of Fan Rotation…………………………………………………………………………………………….. 5-10
Compressed Air Supply………………………………………………………………………………………………..5-11
Air Regulator / Filter…………………………………………………………………………………………………….5-11
Electric Timer…………………………………………………………………………………………………………….. 5-12
Compressed Air Supply………………………………………………………………………………………………. 5-13
Filter Maintenance……………………………………………………………………………………………………… 5-13
Routine Maintenance…………………………………………………………………………………………………. 5-14
Troubleshooting Guide……………………………………………………………………………………………….. 5-15
Water Injection Pump Assembly…………………………………………………………………………………… 5-16
Pump Specifications…………………………………………………………………………………………………… 5-17
Torque Requirements…………………………………………………………………………………………………. 5-17
Servicing Instructions…………………………………………………………………………………………………. 5-17
Servicing the Plunger Packings……………………………………………………………………………………. 5-17
Reassembling Plunger Packings………………………………………………………………………………….. 5-18
Servicing the Pump Valves………………………………………………………………………………………….. 5-18
Reassembling Valve Parts………………………………………………………………………………………….. 5-18
Servicing the Crankshaft…………………………………………………………………………………………….. 5-19
Servicing the Crossheads…………………………………………………………………………………………… 5-19
Water Tanks………………………………………………………………………………………………………………. 5-20
Water Injection Relief Valve…………………………………………………………………………………………. 5-21
Water Injection Control……………………………………………………………………………………………….. 5-22
Water Injection Basic Circuit……………………………………………………………………………………….. 5-24
Water Pump…………………………………………………………………………………………………………………… 5-25
Replacing Piston Cup Seals………………………………………………………………………………………… 5-25
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Replacing Suction and Discharge Valves………………………………………………………………………. 5-26
Replacing Power End Bearings……………………………………………………………………………………. 5-27
Servicing the Wrist Pin Bearings………………………………………………………………………………….. 5-28
Fastener Torque Requirements……………………………………………………………………………………. 5-28
Recommended Lubricants………………………………………………………………………………………….. 5-29
Water Pump Motor Repair…………………………………………………………………………………………… 5-29
Water Injection Hydraulic Control Valve Repair………………………………………………………………. 5-29
Water Pump Drive Coupling………………………………………………………………………………………… 5-29
Level and Flow Transducer…………………………………………………………………………………………. 5-29
Hydraulic Motor…………………………………………………………………………………………………………….. 5-30
Hydraulic Motor Repair Information………………………………………………………………………………. 5-30
Disassembly……………………………………………………………………………………………………………… 5-31
Reassembly………………………………………………………………………………………………………………. 5-33
Wheel Motor……………………………………………………………………………………………………………… 5-35
Wheel Motor with Guard……………………………………………………………………………………………… 5-35
Pump Identifcation……………………………………………………………………………………………………… 5-36
Notes…………………………………………………………………………………………………………………………….. 5-37
Section 6 – Mast / Rotary Drive / Pipe Rack………………………………6-1
Section 6 Contents………………………………………………………………………………………………………….. 6-3
Mast Weldment………………………………………………………………………………………………………………… 6-5
Mast Repair………………………………………………………………………………………………………………… 6-5
Weld Inspection Schedule……………………………………………………………………………………………….. 6-6
Mast Inspection…………………………………………………………………………………………………………… 6-6
Mast Assembly and Installation……………………………………………………………………………………….. 6-7
Mast Assembly……………………………………………………………………………………………………………. 6-7
Mast Pivot Caps………………………………………………………………………………………………………….. 6-8
Mast Elevate Cylinders…………………………………………………………………………………………………. 6-9
Angle Drilling………………………………………………………………………………………………………………. 6-9
Mast / Drill Without Mast…………………………………………………………………………………………….. 6-10
Mast Assembly……………………………………………………………………………………………………………6-11
Raising the Mast………………………………………………………………………………………………………….6-11
Hoist / Pulldown Cylinder………………………………………………………………………………………………. 6-13
Hoist / Pulldown Cylinder……………………………………………………………………………………………. 6-13
Feed Cylinder Service………………………………………………………………………………………………… 6-14
Feed Cylinder Removal………………………………………………………………………………………………. 6-15
Installation………………………………………………………………………………………………………………… 6-16
General Information……………………………………………………………………………………………………. 6-17
Hoist / Pulldown Cable…………………………………………………………………………………………………… 6-18
Hoist / Pulldown Cable Adjustment………………………………………………………………………………. 6-18
Hoist / Pulldown Cable Replacement……………………………………………………………………………. 6-19
Wire Rope………………………………………………………………………………………………………………… 6-20
Rotary Drive Gearbox…………………………………………………………………………………………………….. 6-21
Alignment Procedure………………………………………………………………………………………………….. 6-21
Rotary Drive Assembly……………………………………………………………………………………………….. 6-22
Rotary Drive – Removal from Mast………………………………………………………………………………. 6-23
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Rotary Drive – Installation…………………………………………………………………………………………… 6-23
Single Motor Rotary Drive Gearbox……………………………………………………………………………… 6-24
Air Swivel (Dual Seal Style)…………………………………………………………………………………………. 6-25
Service…………………………………………………………………………………………………………………….. 6-25
Rotary Drive Motor – Repair………………………………………………………………………………………… 6-26
Top Mast Drive Transmission TM2132-4 Manual……………………………………………………………. 6-27
Preface…………………………………………………………………………………………………………………….. 6-28
General Working Instructions………………………………………………………………………………………. 6-29
Work Safety………………………………………………………………………………………………………………. 6-30
Symbol Explanation……………………………………………………………………………………………………. 6-30
Conversion Table……………………………………………………………………………………………………….. 6-31
Torque Limit Table Grade 5 UNC…………………………………………………………………………………. 6-32
Torque Limit Table Grade 5 UNF………………………………………………………………………………….. 6-33
Torque Limit Table Grade 8 UNC…………………………………………………………………………………. 6-34
Torque Limit Table Grade 8 UNF………………………………………………………………………………….. 6-35
Inscription of the Model Identification Plate……………………………………………………………………. 6-36
Disassembly Transmission………………………………………………………………………………………….. 6-37
Assembly Transmission………………………………………………………………………………………………. 6-44
Rotary Drive Motor…………………………………………………………………………………………………….. 6-62
Winch Assembly……………………………………………………………………………………………………………. 6-63
Precautions on the use of Winches……………………………………………………………………………… 6-63
Wire Rope………………………………………………………………………………………………………………… 6-63
Wedge Sockets…………………………………………………………………………………………………………. 6-65
Grooved Drums…………………………………………………………………………………………………………. 6-65
Plain (Smooth) Drums………………………………………………………………………………………………… 6-66
Drums – Multiple Layers……………………………………………………………………………………………… 6-66
Deck Wrench…………………………………………………………………………………………………………………. 6-68
Deck Wrench…………………………………………………………………………………………………………….. 6-68
H.O.B.O. Wrench……………………………………………………………………………………………………………. 6-69
H.O.B.O Wrench……………………………………………………………………………………………………….. 6-69
Tong Dies…………………………………………………………………………………………………………………. 6-70
Optional Hydraulic Operated Bit Basket – H.O.B.B…………………………………………………………. 6-70
Pipe Positioner………………………………………………………………………………………………………………. 6-71
Pipe Positioner………………………………………………………………………………………………………….. 6-71
Carousel Pipe Rack……………………………………………………………………………………………………….. 6-72
Carousel Pipe Rack……………………………………………………………………………………………………. 6-72
Chain Drive – Adjustment / Replace……………………………………………………………………………… 6-72
Pipe Rack Bearings – Replace…………………………………………………………………………………….. 6-73
Carousel Top Tube Bearing – Replace………………………………………………………………………….. 6-74
Carousel Lower Bearing – Replace………………………………………………………………………………. 6-76
Upper Pivot Support Bearing……………………………………………………………………………………….. 6-77
Carousel Pivot Support Upper Bearing – Replace………………………………………………………….. 6-78
Pivot Support Pipe Lower Bushing……………………………………………………………………………….. 6-79
Carousel Pivot Support Lower Bearing – Replace………………………………………………………….. 6-80
Mid Point Carousel Pivot Support………………………………………………………………………………… 6-81
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April, 10 Version 1 Int-13 SKF Introduction
Contents
Top Sub Saver……………………………………………………………………………………………………………….. 6-82
Replacement Procedure……………………………………………………………………………………………… 6-82
Notes…………………………………………………………………………………………………………………………….. 6-83
Section 7 – Hydraulic Systems………………………………………………… 7-1
Section 7 Contents………………………………………………………………………………………………………….. 7-3
Hydraulic Symbols………………………………………………………………………………………………………….. 7-7
Hydraulic Symbols……………………………………………………………………………………………………….. 7-7
Hydraulic Tank………………………………………………………………………………………………………………… 7-9
Hydraulic Tank…………………………………………………………………………………………………………….. 7-9
Hydraulic System………………………………………………………………………………………………………. 7-10
Pressure Setting Sequence……………………………………………………………………………………………..7-11
Pressure Setting Sequence…………………………………………………………………………………………..7-11
Hydraulic System………………………………………………………………………………………………………..7-11
Main Return and Case Drain Filter………………………………………………………………………………….. 7-12
Routine Maintenance…………………………………………………………………………………………………. 7-13
Changing Filter Elements……………………………………………………………………………………………. 7-13
Main Hydraulic Pumps…………………………………………………………………………………………………… 7-14
Pump Identification…………………………………………………………………………………………………….. 7-14
Right Track / Left Track / Rotation Pumps………………………………………………………………………. 7-15
Break Test Procedure Sk Infinity Series Drills……………………………………………………………….. 7-15
Setting Procedure………………………………………………………………………………………………………. 7-15
Technical Data…………………………………………………………………………………………………………… 7-17
Main Pump Adjustments……………………………………………………………………………………………… 7-18
Charge Pressure, High Pressure, P.O.R and Zero Position settings…………………………………. 7-19
Set Charge Pressure – 320psi (22 bar)…………………………………………………………………………. 7-19
Linde HPR-02 Self-Regulating Pumps………………………………………………………………………….. 7-20
Cross section of Single Pump……………………………………………………………………………………… 7-22
Operational Parameters……………………………………………………………………………………………… 7-24
Linde HPR-02 Pump Schematic…………………………………………………………………………………… 7-25
Controls……………………………………………………………………………………………………………………. 7-26
Dimensions……………………………………………………………………………………………………………….. 7-29
Charge Pumps………………………………………………………………………………………………………….. 7-30
Setting Linde HPR-02 Main pumps – Neutral Setting…………………………………………………….. 7-31
Setting Linde HPR-02 Main pumps – Pressure Settings…………………………………………………. 7-32
Setting Linde HPR-02 Main pumps – Pre-setup Checks…………………………………………………. 7-33
Main Pumps Linde HPR-02…………………………………………………………………………………………. 7-34
Charge Circuit……………………………………………………………………………………………………………….. 7-35
Charge Circuit Schematic……………………………………………………………………………………………. 7-35
Charge Circuit…………………………………………………………………………………………………………… 7-36
Routine Maintenance…………………………………………………………………………………………………. 7-37
Changing Filter Elements……………………………………………………………………………………………. 7-38
Main Pumps Circuit……………………………………………………………………………………………………….. 7-39
Main Pumps Circuit……………………………………………………………………………………………………. 7-39
Loop Filters…………………………………………………………………………………………………………………… 7-40
Loop Filters……………………………………………………………………………………………………………….. 7-40
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Bucyrus International, Inc.®
SKF Introduction Int-14 April, 10 Version 1
Contents
Routine Maintenance…………………………………………………………………………………………………. 7-40
Loop Filter Cross Section……………………………………………………………………………………………. 7-41
Filter Assembly Loop………………………………………………………………………………………………….. 7-42
Changing Filter Elements……………………………………………………………………………………………. 7-43
Diverter Valve………………………………………………………………………………………………………………… 7-44
Closed Loop Pump Circuit…………………………………………………………………………………………… 7-44
Operation………………………………………………………………………………………………………………….. 7-44
Diverter Valve……………………………………………………………………………………………………………. 7-44
Rotation Circuit……………………………………………………………………………………………………………… 7-45
Rotation / Tram Motor Circuit Schematic……………………………………………………………………….. 7-45
Rotation Circuit………………………………………………………………………………………………………….. 7-46
Rotary Drive Gearbox Motor…………………………………………………………………………………………… 7-47
Variable Displacement Motor AA6M……………………………………………………………………………… 7-47
Tram Circuit…………………………………………………………………………………………………………………… 7-61
Tram Circuit………………………………………………………………………………………………………………. 7-61
Basic Rotation Circuit…………………………………………………………………………………………………. 7-62
Tram Circuit Schematic………………………………………………………………………………………………. 7-63
Counterbalance Valves………………………………………………………………………………………………….. 7-64
Counterbalance Valve Adjustment……………………………………………………………………………….. 7-64
Pilot Control Manifold……………………………………………………………………………………………………. 7-65
Pilot Control Manifold…………………………………………………………………………………………………. 7-65
Pilot Control Manifold Assembly…………………………………………………………………………………… 7-66
Control Valve Assembly………………………………………………………………………………………………. 7-67
Torque Control…………………………………………………………………………………………………………… 7-74
Parts List………………………………………………………………………………………………………………….. 7-75
Proportional Pulldown………………………………………………………………………………………………… 7-76
Proportional Valve Set Up…………………………………………………………………………………………… 7-77
Auto Pulldown Card……………………………………………………………………………………………………. 7-77
Auxiliary Pump Circuit…………………………………………………………………………………………………… 7-78
Spools……………………………………………………………………………………………………………………… 7-78
Electro – Hydraulic Kit (24V DC)………………………………………………………………………………….. 7-78
Feed and Auxiliary Pump Circuit………………………………………………………………………………….. 7-80
Auxiliary Pump Circuit Schematic………………………………………………………………………………… 7-81
Feed and Auxiliary Functions Pump……………………………………………………………………………… 7-82
Pump Replacement – Start Up…………………………………………………………………………………….. 7-82
Jack Control and Mast Elevating Circuit…………………………………………………………………………. 7-84
Jack Control and Mast Elevating Circuit Schematic………………………………………………………… 7-84
Jack Control and Mast Elevating Circuit………………………………………………………………………… 7-85
Levelling Jack Cylinders………………………………………………………………………………………………… 7-86
Jack Leg Cylinder………………………………………………………………………………………………………. 7-86
Counterbalance Valve Test Procedure………………………………………………………………………….. 7-86
Mast Elevating Cylinders……………………………………………………………………………………………….. 7-87
Internal Counterbalance Valve…………………………………………………………………………………….. 7-87
Auxiliary Circuit…………………………………………………………………………………………………………….. 7-89
Auxiliary Functions Circuit…………………………………………………………………………………………… 7-89
4WE6 Auxiliary Valves………………………………………………………………………………………………… 7-91
Exploded View of 4WE6……………………………………………………………………………………………… 7-93
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Hydraulic Operated Breakout Wrench…………………………………………………………………………….. 7-94
H.O.B.O Wrench……………………………………………………………………………………………………….. 7-94
Setting of H.O.B.O Sequence Valves……………………………………………………………………………. 7-95
H.O.B.O Float Valve…………………………………………………………………………………………………… 7-95
Cooler Fan Circuit………………………………………………………………………………………………………….. 7-96
Cooler Fan Circuit……………………………………………………………………………………………………… 7-96
Setting Cooler Fan Speed…………………………………………………………………………………………… 7-96
Basic Cooler Fan Circuit……………………………………………………………………………………………… 7-98
Cooler Fan Motor…………………………………………………………………………………………………………… 7-99
Hydraulic Motor…………………………………………………………………………………………………………. 7-99
Cooler Fan Motor Assembly………………………………………………………………………………………. 7-101
Hydraulic Feed Circuit………………………………………………………………………………………………….. 7-103
Hydraulic Feed Circuit………………………………………………………………………………………………. 7-103
Hoist and Pulldown Control………………………………………………………………………………………….. 7-105
M-22 Valve……………………………………………………………………………………………………………… 7-105
Feed Valve Assembly…………………………………………………………………………………………………… 7-107
Feed Valve Assembly……………………………………………………………………………………………….. 7-107
Control Valve Assembly……………………………………………………………………………………………….. 7-109
Technical Data…………………………………………………………………………………………………………. 7-109
Hydraulic Cylinder Repair……………………………………………………………………………………………… 7-111
Hydraulic Cylinders……………………………………………………………………………………………………7-111
General Information……………………………………………………………………………………………………7-112
H Head…………………………………………………………………………………………………………………….7-114
N Head…………………………………………………………………………………………………………………….7-115
Z Head……………………………………………………………………………………………………………………..7-116
Z Head (Two Piece)……………………………………………………………………………………………………7-117
K Head…………………………………………………………………………………………………………………….7-118
M Head…………………………………………………………………………………………………………………….7-119
Z Piston………………………………………………………………………………………………………………….. 7-120
Z Piston (Threaded)…………………………………………………………………………………………………. 7-121
H and K Piston………………………………………………………………………………………………………… 7-122
M Piston…………………………………………………………………………………………………………………. 7-123
N Piston………………………………………………………………………………………………………………….. 7-126
Notes…………………………………………………………………………………………………………………………… 7-127
Section 8 – Electrical Components…………………………………………..8-1
Section 8 Contents………………………………………………………………………………………………………….. 8-3
Electrical Locator…………………………………………………………………………………………………………….. 8-5
Electrical Component Location………………………………………………………………………………………. 8-5
Jump Starting………………………………………………………………………………………………………………….. 8-8
Jump Starting……………………………………………………………………………………………………………… 8-8
Batteries……………………………………………………………………………………………………………………….. 8-10
Batteries…………………………………………………………………………………………………………………… 8-10
Welding Precautions……………………………………………………………………………………………………….8-11
Welding Precautions……………………………………………………………………………………………………8-11
BI620416
Bucyrus International, Inc.®
SKF Introduction Int-16 April, 10 Version 1
Contents
Electrical Components…………………………………………………………………………………………………… 8-12
Electrical Circuits……………………………………………………………………………………………………….. 8-12
Transducers……………………………………………………………………………………………………………… 8-12
EP Levers…………………………………………………………………………………………………………………. 8-13
Joystick Adjustments………………………………………………………………………………………………….. 8-14
Vigilante Guide………………………………………………………………………………………………………………. 8-16
Important Information…………………………………………………………………………………………………. 8-16
PLC…………………………………………………………………………………………………………………………. 8-17
Touchscreen……………………………………………………………………………………………………………… 8-20
Laser Depth System…………………………………………………………………………………………………… 8-21
Start Up and Shutdown………………………………………………………………………………………………. 8-24
Hydraulic Function Enable………………………………………………………………………………………….. 8-24
Alarms……………………………………………………………………………………………………………………… 8-24
Solenoid Control………………………………………………………………………………………………………… 8-25
Auto Lube…………………………………………………………………………………………………………………. 8-27
Gauges…………………………………………………………………………………………………………………….. 8-27
Level Switches………………………………………………………………………………………………………….. 8-30
Dust Suppression………………………………………………………………………………………………………. 8-30
Acknowledgements……………………………………………………………………………………………………. 8-31
Disclaimers……………………………………………………………………………………………………………….. 8-31
Notes…………………………………………………………………………………………………………………………….. 8-32
N.B: For further information on specific electronic components, please refer to
Vendor Documents in table of contents on Service Manual CD.
Section 9 – Lubrication and Preventive Maintenance………………..9-1
Section 9 Contents………………………………………………………………………………………………………….. 9-3
Central Lube System……………………………………………………………………………………………………….. 9-5
Auto Lube Basic Operation…………………………………………………………………………………………… 9-5
Central Lube Tank Assembly…………………………………………………………………………………………. 9-6
Auto Lube Grease Pump………………………………………………………………………………………………. 9-7
Auto Lube Tube Pump………………………………………………………………………………………………… 9-12
Graco Vent Valve……………………………………………………………………………………………………….. 9-16
Central Lube System Circuit………………………………………………………………………………………… 9-17
Basic Operational Principles of Auto Lube Injectors………………………………………………………… 9-18
SL-V and SL-V XL Injectors………………………………………………………………………………………… 9-18
SL-1 and Sl-11 Injectors……………………………………………………………………………………………… 9-19
SL-32 Injectors………………………………………………………………………………………………………….. 9-20
Typical Grease System Circuit…………………………………………………………………………………….. 9-21
First 50 Hours Service………………………………………………………………………………………………… 9-22
Lube Faults / Operation………………………………………………………………………………………………. 9-23
Auto Lube Timer………………………………………………………………………………………………………… 9-24
Lube Pressure Screen………………………………………………………………………………………………… 9-24
Air Service Units……………………………………………………………………………………………………………. 9-25
Filter Regulator………………………………………………………………………………………………………….. 9-25
Air Line Oiler……………………………………………………………………………………………………………… 9-26
Soft Start Dump Valve………………………………………………………………………………………………… 9-27
Air Service Unit………………………………………………………………………………………………………….. 9-28
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April, 10 Version 1 Int-17 SKF Introduction
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Pipe Thread Lubricator………………………………………………………………………………………………….. 9-29
Air Operator Pipe Thread Pump…………………………………………………………………………………… 9-29
Filter Locator…………………………………………………………………………………………………………………. 9-37
Filter Locator Assembly………………………………………………………………………………………………. 9-37
Lubrication and Preventive Maintenance………………………………………………………………………… 9-38
General Lubrication……………………………………………………………………………………………………. 9-38
Equipment Lubrication………………………………………………………………………………………………… 9-38
Care of Lubrication Points…………………………………………………………………………………………… 9-38
Safety………………………………………………………………………………………………………………………. 9-39
Track Gear………………………………………………………………………………………………………………… 9-40
Engine Maintenance…………………………………………………………………………………………………… 9-41
Air Cleaners………………………………………………………………………………………………………………. 9-42
Air Filter Elements……………………………………………………………………………………………………… 9-42
Alternator Maintenance………………………………………………………………………………………………. 9-42
Pump Drive and Drive Shaft Maintenance…………………………………………………………………….. 9-43
Compressor Maintenance…………………………………………………………………………………………… 9-43
Cooler Packs…………………………………………………………………………………………………………….. 9-43
A-frame and Pivot Point Maintenance…………………………………………………………………………… 9-45
Pull Down and Hoist Ropes and Sheaves Maintenance………………………………………………….. 9-45
Rotary Head Maintenance…………………………………………………………………………………………… 9-45
Hydraulic System Maintenance……………………………………………………………………………………. 9-47
Hydraulic Maintenance……………………………………………………………………………………………….. 9-47
Water Pump Maintenance…………………………………………………………………………………………… 9-47
Cab Maintenance………………………………………………………………………………………………………. 9-47
Air Conditioner Maintenance……………………………………………………………………………………….. 9-49
Battery Maintenance………………………………………………………………………………………………….. 9-49
Lubrication System Maintenance…………………………………………………………………………………. 9-49
Fire Suppression Maintenance…………………………………………………………………………………….. 9-49
Drill Folding Stairway – Inspection Requirements…………………………………………………………… 9-51
Weld Inspection Schedule……………………………………………………………………………………………… 9-52
Weld Inspection Schedule SK Series……………………………………………………………………………. 9-52
Track and Sprocket Inspection……………………………………………………………………………………….. 9-53
Track Inspection and Wear Limit Guide………………………………………………………………………… 9-53
Sprocket Wear Patterns……………………………………………………………………………………………… 9-58
Lubrication Recommendations………………………………………………………………………………………. 9-64
Lubrication Recommendations…………………………………………………………………………………….. 9-64
Lubrication and Maintenance Chart – 250hr……………………………………………………………………. 9-65
Lubrication and Maintenance Chart – 500hr……………………………………………………………………. 9-75
Lubrication and Maintenance Chart – 1000hr………………………………………………………………….. 9-86
Lubrication and Maintenance Chart – 2000hr………………………………………………………………….. 9-97
Lubricant Specifications………………………………………………………………………………………………. 9-109
Hydraulic System…………………………………………………………………………………………………….. 9-109
Hydraulic Tank Capacity……………………………………………………………………………………………. 9-109
Compressor Lubrication……………………………………………………………………………………………..9-110
Compressor Lubricant Specifications……………………………………………………………………………9-110
Lubricating Grease…………………………………………………………………………………………………….9-111
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Gear Lubricant…………………………………………………………………………………………………………..9-111
Scheduled Oil Sampling Analysis…………………………………………………………………………………9-111
Torque Values for Split Flange Connections…………………………………………………………………..9-112
Torque Values for Split Flange Connections………………………………………………………………….9-112
Procedure No. 1-87 Revision A……………………………………………………………………………………9-114
Notes…………………………………………………………………………………………………………………………….9-115Section 1 Contents………………………………………………………………………………………………………….. 1-3
Safety……………………………………………………………………………………………………………………………… 1-5
Personal Protective Equipment……………………………………………………………………………………… 1-5
Noise…………………………………………………………………………………………………………………………. 1-5
Electrical Contact………………………………………………………………………………………………………… 1-5
Contaminated Air…………………………………………………………………………………………………………. 1-6
Moving and Rotating Parts……………………………………………………………………………………………. 1-7
High Pressure Air or Fluid…………………………………………………………………………………………….. 1-7
Before Operation…………………………………………………………………………………………………………. 1-7
During Operation…………………………………………………………………………………………………………. 1-8
Maintenance……………………………………………………………………………………………………………… 1-10
Safety Locator…………………………………………………………………………………………………………….1-11
Notes…………………………………………………………………………………………………………………………….. 1-14
Section 2 – Operator’s Cab / Controls……………………………………… 2-1
Section 2 Contents………………………………………………………………………………………………………….. 2-3
Graphic Symbol Legend………………………………………………………………………………………………….. 2-5
Graphic Symbol Legend……………………………………………………………………………………………….. 2-5
Warning Decals……………………………………………………………………………………………………………….. 2-9
Warning Decals…………………………………………………………………………………………………………… 2-9
Operator Control and Instrument Panels………………………………………………………………………… 2-12
Control Panels…………………………………………………………………………………………………………… 2-12
Right Hand Control Panel……………………………………………………………………………………………. 2-12
Instrument Panel……………………………………………………………………………………………………….. 2-14
Circuit Breakers…………………………………………………………………………………………………………. 2-15
Light Switches…………………………………………………………………………………………………………… 2-15
System Pressure Gauge Panel……………………………………………………………………………………. 2-16
Left Hand Control Panels……………………………………………………………………………………………. 2-18
Cab Foot Controls……………………………………………………………………………………………………… 2-22
Thread Grease Switch………………………………………………………………………………………………… 2-22
Pipe Safety Arm Override Switch…………………………………………………………………………………. 2-22
Machine Stability…………………………………………………………………………………………………………… 2-23
Tramming Procedure for SK Series Drills……………………………………………………………………… 2-23
Track Adjustments……………………………………………………………………………………………………… 2-23
New Machine Procedure…………………………………………………………………………………………….. 2-24
General Maintenance Checks While Tramming……………………………………………………………… 2-24
Roller Locations…………………………………………………………………………………………………………. 2-25
Temperature and Condition Record Chart for Walking…………………………………………………….. 2-26
Propelling the Machine……………………………………………………………………………………………….. 2-27
Stability Limits…………………………………………………………………………………………………………… 2-29
SKF Transient Stability Limits………………………………………………………………………………………. 2-30
Cab Heater…………………………………………………………………………………………………………………….. 2-31
Cab Heater Fault Isolation…………………………………………………………………………………………… 2-31
Air Conditioner………………………………………………………………………………………………………………. 2-32
T7 Series Split System Air Conditioning Manual…………………………………………………………….. 2-32
BI620416
Bucyrus International, Inc.®
SKF Introduction Int-6 April, 10 Version 1
Contents
Section 1.0 Technical Data and Control Settings……………………………………………………………. 2-33
Section 2.0 Installation and Commissioning…………………………………………………………………… 2-35
Section 3.0 Routine Maintenance Procedures……………………………………………………………….. 2-41
Section 4.0 Fault Diagnosis…………………………………………………………………………………………. 2-42
Section 5.0 Reference Drawings………………………………………………………………………………….. 2-51
Notes…………………………………………………………………………………………………………………………….. 2-56
Section 3 – Main Frame / Crawlers……………………………………………3-1
Section 3 Contents………………………………………………………………………………………………………….. 3-3
Main Frame Repair – General…………………………………………………………………………………………… 3-5
Main Frame Repair………………………………………………………………………………………………………. 3-5
Weld Inspection Schedule……………………………………………………………………………………………….. 3-6
Main Frame………………………………………………………………………………………………………………… 3-6
Levelling Jacks……………………………………………………………………………………………………………….. 3-7
Levelling Jacks Cylinder……………………………………………………………………………………………….. 3-7
Levelling Jacks……………………………………………………………………………………………………………. 3-8
Limit Switch………………………………………………………………………………………………………………… 3-8
Levelling Jack Cylinders……………………………………………………………………………………………….. 3-8
Mast Elevating Cylinders…………………………………………………………………………………………………. 3-9
Mast Elevating Cylinders………………………………………………………………………………………………. 3-9
Internal Counterbalance Valve…………………………………………………………………………………….. 3-10
Crawler Assembly………………………………………………………………………………………………………….. 3-12
Crawler Assembly………………………………………………………………………………………………………. 3-12
Parts List………………………………………………………………………………………………………………….. 3-13
Crawler Component Repair…………………………………………………………………………………………. 3-13
Tramming………………………………………………………………………………………………………………………. 3-14
Maintenance checks for Tramming for SK Series Drills………………………………………………….. 3-14
Track Adjustments……………………………………………………………………………………………………… 3-14
New Machine Procedure…………………………………………………………………………………………….. 3-15
General Maintenance Checks While Tramming……………………………………………………………… 3-15
Roller Locations…………………………………………………………………………………………………………. 3-16
Temperature and Condition Record Chart for Walking…………………………………………..3-17
Metric Bolt Torque Specifications…………………………………………………………………………………… 3-18
Metric Bolt Torque Specifications…………………………………………………………………………………. 3-18
Track Tension Adjustment……………………………………………………………………………………………… 3-19
Before Operating the Machine…………………………………………………………………………………….. 3-19
General Maintenance…………………………………………………………………………………………………. 3-19
Track Assembly…………………………………………………………………………………………………………. 3-20
Idler Unit Description………………………………………………………………………………………………….. 3-21
Hydraulic Tensioner……………………………………………………………………………………………………. 3-22
Repair………………………………………………………………………………………………………………………. 3-22
Nitrogen Tensioner…………………………………………………………………………………………………….. 3-23
Nitrogen Tensioner – Filling Instructions……………………………………………………………………….. 3-24
Nitrogen Tensioner – Pressure Check…………………………………………………………………………… 3-25
Nitrogen Tensioner – Pressure Release………………………………………………………………………… 3-25
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Hydraulic Tensioner………………………………………………………………………………………………………. 3-26
Hydraulic Tensioner Assembly…………………………………………………………………………………….. 3-26
Repair………………………………………………………………………………………………………………………. 3-26
Track Chain…………………………………………………………………………………………………………………… 3-27
Track Chain – Separate……………………………………………………………………………………………… 3-27
Track Chain Repair……………………………………………………………………………………………………. 3-28
Track Shoes Installation…………………………………………………………………………………………………. 3-30
Track Link Position…………………………………………………………………………………………………….. 3-30
Track Shoe – Mounting to Track Chain…………………………………………………………………………. 3-30
Track Shoe Bolt Torque (Direct Torque Method)……………………………………………………………… 3-32
Bolt Torque KN111……………………………………………………………………………………………………… 3-32
Track Shoe Bolt Torque (Torque Turn Method)……………………………………………………………….. 3-33
Bolt Torque KN111……………………………………………………………………………………………………… 3-33
Track Chain and Shoe Installation………………………………………………………………………………….. 3-34
Track Chain with Shoes……………………………………………………………………………………………… 3-34
Track Chain and Shoe – Assembly and Installation………………………………………………………… 3-34
Final Drive Unit……………………………………………………………………………………………………………… 3-36
General Description……………………………………………………………………………………………………. 3-36
Removal from Track Frame…………………………………………………………………………………………. 3-37
Installation into Track Frame……………………………………………………………………………………….. 3-38
Final Drive Maintenance……………………………………………………………………………………………… 3-39
Final Drive Oil……………………………………………………………………………………………………………. 3-40
Final Drive Assembly………………………………………………………………………………………………….. 3-42
Parking Brake – Description………………………………………………………………………………………… 3-43
Final Drive – Disconnect and Parking Brake………………………………………………………………….. 3-44
Towing Procedure – Gear Drive Disconnect………………………………………………………………….. 3-44
Parking Brake – Description………………………………………………………………………………………… 3-45
Parking Brake – Removal and Installation…………………………………………………………………….. 3-45
Repair Manual Final Drive Model F100 – General Information…………………………………………. 3-46
Repair Manual Final Drive Model F100 – Safety Instructions…………………………………………… 3-51
Repair Manual Final Drive Model F100 – General Specifications……………………………………… 3-55
Disassembly and Assembly Operations………………………………………………………………………… 3-64
Repair Manual Final Drive Model F100 – Troubleshooting………………………………………………. 3-98
Repair Manual Final Drive Model F100 – Special Tools…………………………………………………… 3-99
Idler Unit……………………………………………………………………………………………………………………… 3-100
Idler Unit – Assembly………………………………………………………………………………………………… 3-100
Idler Unit – Removal…………………………………………………………………………………………………. 3-103
Track and Support Rollers……………………………………………………………………………………………. 3-105
Track Roller Assembly………………………………………………………………………………………………. 3-105
Track Roller – Removal and Disassembly…………………………………………………………………… 3-106
Support Roller – Removal and Disassembly………………………………………………………………… 3-106
Track and Support Roller – Assembly…………………………………………………………………………. 3-107
Track and Support Roller – Test and Install………………………………………………………………….. 3-108
Track and Sprocket Inspection……………………………………………………………………………………….3-110
Track Inspection and Wear Limit Guide………………………………………………………………………..3-110
Sprocket Wear Patterns……………………………………………………………………………………………..3-115
BI620416
Bucyrus International, Inc.®
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Contents
Auxiliary Crane……………………………………………………………………………………………………………. 3-121
Hydraulic Crane – Rear Deck Crane Palfinger PC1300…………………………………………………. 3-121
Rear Deck Crane Palfinger PC1300 Service information………………………………………………. 3-122
Checking Bolted Connections……………………………………………………………………………………. 3-122
Maintenance Chart…………………………………………………………………………………………………… 3-123
Lubrication………………………………………………………………………………………………………………. 3-125
Hydraulic Fluids……………………………………………………………………………………………………….. 3-128
Oil Change / Oil Maintenance……………………………………………………………………………………. 3-129
Cleaning Agents and Equipment………………………………………………………………………………… 3-130
Repairing Paint Damage…………………………………………………………………………………………… 3-131
Removal From Service and Disposal………………………………………………………………………….. 3-131
Notes…………………………………………………………………………………………………………………………… 3-132
Section 4 – Engine / Drive Train / Compressor………………………….4-1
Section 4 Contents………………………………………………………………………………………………………….. 4-3
Power Group Locator………………………………………………………………………………………………………. 4-5
Power Group Locator…………………………………………………………………………………………………… 4-5
Test Point Locator…………………………………………………………………………………………………………… 4-6
Test Point Locator………………………………………………………………………………………………………… 4-6
Cummins Engine…………………………………………………………………………………………………………….. 4-8
Cummins Engine…………………………………………………………………………………………………………. 4-8
Oil Reserve Systems……………………………………………………………………………………………………. 4-9
LED Monitor Readings……………………………………………………………………………………………….. 4-10
Adjustment of Running Oil Level………………………………………………………………………………….. 4-10
Wiring Diagram – Oil Reserve Basic Circuit…………………………………………………………………….4-11
Oil Pressure Switch……………………………………………………………………………………………………..4-11
Oil Reserve System……………………………………………………………………………………………………..4-11
Troubleshooting…………………………………………………………………………………………………………. 4-12
Maintenance……………………………………………………………………………………………………………… 4-13
Engine and Compressor Air Cleaners…………………………………………………………………………….. 4-14
Engine and Compressor Air Cleaner Service Assembly………………………………………………….. 4-14
Engine and Compressor Air Cleaner Service…………………………………………………………………. 4-15
Flexible Drive Coupling………………………………………………………………………………………………….. 4-18
Flexible Drive Coupling Service…………………………………………………………………………………… 4-18
Pump Drive……………………………………………………………………………………………………………………. 4-20
Pump Drive Assembly – Removal and Replacement………………………………………………………. 4-20
Pump Drive Gearbox………………………………………………………………………………………………….. 4-21
Pump Drive Gearbox Repair……………………………………………………………………………………….. 4-21
Hydraulic Pumps…………………………………………………………………………………………………………… 4-23
Hydraulic Pumps……………………………………………………………………………………………………….. 4-23
Hydraulic Pumps – Removal and Replacement……………………………………………………………… 4-25
Compressor Installation…………………………………………………………………………………………………. 4-26
1700cfm / 100psi Compressor…………………………………………………………………………………….. 4-26
Safety………………………………………………………………………………………………………………………. 4-27
Compressor Installation………………………………………………………………………………………………. 4-30
Compressor Drive Coupling………………………………………………………………………………………… 4-31
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Bucyrus International, Inc.®
April, 10 Version 1 Int-9 SKF Introduction
Contents
Compressor Alignment……………………………………………………………………………………………….. 4-32
Mounting Instructions for Arcusaflex™ Flywheel Couplings……………………………………………… 4-33
Taper-Loc Bushing Installation – Model AC-T5.SN. F2. V1. 3535……………………………………… 4-34
Tightening Torques for ARCUSAFLEX™ Flywheel Couplings………………………………………….. 4-34
Compressor Shaft Seal………………………………………………………………………………………………….. 4-35
Compressor Shaft Seal………………………………………………………………………………………………. 4-35
Low Pressure Compressor…………………………………………………………………………………………….. 4-37
Description……………………………………………………………………………………………………………….. 4-37
Compressed Air Functions………………………………………………………………………………………….. 4-37
Compressor Inlet Valve Control System………………………………………………………………………… 4-41
Inlet Valve…………………………………………………………………………………………………………………. 4-42
Compressor Regulation………………………………………………………………………………………………. 4-44
Relieving Regulators………………………………………………………………………………………………….. 4-45
Reducing Regulators………………………………………………………………………………………………….. 4-47
System Blowdown Valve…………………………………………………………………………………………….. 4-49
Running Blowdown Valve……………………………………………………………………………………………. 4-50
Running Blowdown Maintenance…………………………………………………………………………………. 4-51
Compressor Air and Oil Circuits – 1700cfm @ 100psi…………………………………………………….. 4-52
Operation………………………………………………………………………………………………………………….. 4-55
Compressor Air Circuit Parts List…………………………………………………………………………………. 4-57
Compressor Air Circuit Legend……………………………………………………………………………………. 4-57
Compressor Control Set-up Vented Poppet Inlet – Shutdown………………………………………….. 4-58
Compressor Control Set-up Vented Poppet Inlet – Initial Start-up Below 50psi…………………… 4-59
Compressor Control Set-up Vented Poppet Inlet – Intial Start-up Above 50psi…………………… 4-60
Compressor Control Set-up Vented Poppet Inlet – Run Unloaded……………………………………. 4-61
Compressor Control Set-up Vented Poppet Inlet – Drilling………………………………………………. 4-62
Compressor Maintenance………………………………………………………………………………………………. 4-63
General Maintenance…………………………………………………………………………………………………. 4-63
Discharge Check Valve………………………………………………………………………………………………. 4-65
Compressor Receiver Tank Assembly…………………………………………………………………………… 4-66
Separator Elements……………………………………………………………………………………………………. 4-67
Scavenge Line…………………………………………………………………………………………………………… 4-68
Compressor Discharge Temperature Gauge, Switch and Sender…………………………………….. 4-70
Minimum Pressure Valve…………………………………………………………………………………………….. 4-71
Minimum Pressure / Check Valve Maintenance……………………………………………………………… 4-71
Thermal Bypass Valve………………………………………………………………………………………………… 4-72
Thermal Bypass Valve Maintenance…………………………………………………………………………….. 4-73
Compressor Fluid Filter………………………………………………………………………………………………. 4-75
Changing Filter Elements……………………………………………………………………………………………. 4-76
Oil Stop Valve……………………………………………………………………………………………………………. 4-77
Troubleshooting…………………………………………………………………………………………………………. 4-78
Coolers…………………………………………………………………………………………………………………………. 4-80
Hydraulic Oil / Hydraulic Cooler Assembly…………………………………………………………………….. 4-80
Compressor Oil Cooler……………………………………………………………………………………………….. 4-81
Fan Speed………………………………………………………………………………………………………………… 4-81
Engine Cooler / Radiator…………………………………………………………………………………………….. 4-82
BI620416
Bucyrus International, Inc.®
SKF Introduction Int-10 April, 10 Version 1
Contents
Aluminium Tube Air to Oil Cooler…………………………………………………………………………………… 4-83
Aluminium Tube Air to Oil Cooler – Standard Parts………………………………………………………… 4-83
Removal Replacement……………………………………………………………………………………………….. 4-84
Oil Cooler – Internal Cleaning……………………………………………………………………………………… 4-86
Radiator Cooler……………………………………………………………………………………………………………… 4-88
Typical Radiator Core – Standard Parts………………………………………………………………………… 4-88
Cleaning…………………………………………………………………………………………………………………… 4-89
Tube Removal…………………………………………………………………………………………………………… 4-89
Seal Installation…………………………………………………………………………………………………………. 4-90
Tube Installation………………………………………………………………………………………………………… 4-91
Notes…………………………………………………………………………………………………………………………….. 4-93
Section 5 – Dust Control System………………………………………………5-1
Section 5 Contents………………………………………………………………………………………………………….. 5-3
Dust Control System……………………………………………………………………………………………………….. 5-5
Dust Control Systems…………………………………………………………………………………………………… 5-5
Water Injection………………………………………………………………………………………………………………… 5-7
Basic Specifications…………………………………………………………………………………………………….. 5-7
Technical Data…………………………………………………………………………………………………………….. 5-7
Initial Start-up……………………………………………………………………………………………………………… 5-9
Fan Speed Adjustment…………………………………………………………………………………………………. 5-9
Fan Speed Adjustment…………………………………………………………………………………………………. 5-9
Direction of Fan Rotation…………………………………………………………………………………………….. 5-10
Compressed Air Supply………………………………………………………………………………………………..5-11
Air Regulator / Filter…………………………………………………………………………………………………….5-11
Electric Timer…………………………………………………………………………………………………………….. 5-12
Compressed Air Supply………………………………………………………………………………………………. 5-13
Filter Maintenance……………………………………………………………………………………………………… 5-13
Routine Maintenance…………………………………………………………………………………………………. 5-14
Troubleshooting Guide……………………………………………………………………………………………….. 5-15
Water Injection Pump Assembly…………………………………………………………………………………… 5-16
Pump Specifications…………………………………………………………………………………………………… 5-17
Torque Requirements…………………………………………………………………………………………………. 5-17
Servicing Instructions…………………………………………………………………………………………………. 5-17
Servicing the Plunger Packings……………………………………………………………………………………. 5-17
Reassembling Plunger Packings………………………………………………………………………………….. 5-18
Servicing the Pump Valves………………………………………………………………………………………….. 5-18
Reassembling Valve Parts………………………………………………………………………………………….. 5-18
Servicing the Crankshaft…………………………………………………………………………………………….. 5-19
Servicing the Crossheads…………………………………………………………………………………………… 5-19
Water Tanks………………………………………………………………………………………………………………. 5-20
Water Injection Relief Valve…………………………………………………………………………………………. 5-21
Water Injection Control……………………………………………………………………………………………….. 5-22
Water Injection Basic Circuit……………………………………………………………………………………….. 5-24
Water Pump…………………………………………………………………………………………………………………… 5-25
Replacing Piston Cup Seals………………………………………………………………………………………… 5-25
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April, 10 Version 1 Int-11 SKF Introduction
Contents
Replacing Suction and Discharge Valves………………………………………………………………………. 5-26
Replacing Power End Bearings……………………………………………………………………………………. 5-27
Servicing the Wrist Pin Bearings………………………………………………………………………………….. 5-28
Fastener Torque Requirements……………………………………………………………………………………. 5-28
Recommended Lubricants………………………………………………………………………………………….. 5-29
Water Pump Motor Repair…………………………………………………………………………………………… 5-29
Water Injection Hydraulic Control Valve Repair………………………………………………………………. 5-29
Water Pump Drive Coupling………………………………………………………………………………………… 5-29
Level and Flow Transducer…………………………………………………………………………………………. 5-29
Hydraulic Motor…………………………………………………………………………………………………………….. 5-30
Hydraulic Motor Repair Information………………………………………………………………………………. 5-30
Disassembly……………………………………………………………………………………………………………… 5-31
Reassembly………………………………………………………………………………………………………………. 5-33
Wheel Motor……………………………………………………………………………………………………………… 5-35
Wheel Motor with Guard……………………………………………………………………………………………… 5-35
Pump Identifcation……………………………………………………………………………………………………… 5-36
Notes…………………………………………………………………………………………………………………………….. 5-37
Section 6 – Mast / Rotary Drive / Pipe Rack………………………………6-1
Section 6 Contents………………………………………………………………………………………………………….. 6-3
Mast Weldment………………………………………………………………………………………………………………… 6-5
Mast Repair………………………………………………………………………………………………………………… 6-5
Weld Inspection Schedule……………………………………………………………………………………………….. 6-6
Mast Inspection…………………………………………………………………………………………………………… 6-6
Mast Assembly and Installation……………………………………………………………………………………….. 6-7
Mast Assembly……………………………………………………………………………………………………………. 6-7
Mast Pivot Caps………………………………………………………………………………………………………….. 6-8
Mast Elevate Cylinders…………………………………………………………………………………………………. 6-9
Angle Drilling………………………………………………………………………………………………………………. 6-9
Mast / Drill Without Mast…………………………………………………………………………………………….. 6-10
Mast Assembly……………………………………………………………………………………………………………6-11
Raising the Mast………………………………………………………………………………………………………….6-11
Hoist / Pulldown Cylinder………………………………………………………………………………………………. 6-13
Hoist / Pulldown Cylinder……………………………………………………………………………………………. 6-13
Feed Cylinder Service………………………………………………………………………………………………… 6-14
Feed Cylinder Removal………………………………………………………………………………………………. 6-15
Installation………………………………………………………………………………………………………………… 6-16
General Information……………………………………………………………………………………………………. 6-17
Hoist / Pulldown Cable…………………………………………………………………………………………………… 6-18
Hoist / Pulldown Cable Adjustment………………………………………………………………………………. 6-18
Hoist / Pulldown Cable Replacement……………………………………………………………………………. 6-19
Wire Rope………………………………………………………………………………………………………………… 6-20
Rotary Drive Gearbox…………………………………………………………………………………………………….. 6-21
Alignment Procedure………………………………………………………………………………………………….. 6-21
Rotary Drive Assembly……………………………………………………………………………………………….. 6-22
Rotary Drive – Removal from Mast………………………………………………………………………………. 6-23
BI620416
Bucyrus International, Inc.®
SKF Introduction Int-12 April, 10 Version 1
Contents
Rotary Drive – Installation…………………………………………………………………………………………… 6-23
Single Motor Rotary Drive Gearbox……………………………………………………………………………… 6-24
Air Swivel (Dual Seal Style)…………………………………………………………………………………………. 6-25
Service…………………………………………………………………………………………………………………….. 6-25
Rotary Drive Motor – Repair………………………………………………………………………………………… 6-26
Top Mast Drive Transmission TM2132-4 Manual……………………………………………………………. 6-27
Preface…………………………………………………………………………………………………………………….. 6-28
General Working Instructions………………………………………………………………………………………. 6-29
Work Safety………………………………………………………………………………………………………………. 6-30
Symbol Explanation……………………………………………………………………………………………………. 6-30
Conversion Table……………………………………………………………………………………………………….. 6-31
Torque Limit Table Grade 5 UNC…………………………………………………………………………………. 6-32
Torque Limit Table Grade 5 UNF………………………………………………………………………………….. 6-33
Torque Limit Table Grade 8 UNC…………………………………………………………………………………. 6-34
Torque Limit Table Grade 8 UNF………………………………………………………………………………….. 6-35
Inscription of the Model Identification Plate……………………………………………………………………. 6-36
Disassembly Transmission………………………………………………………………………………………….. 6-37
Assembly Transmission………………………………………………………………………………………………. 6-44
Rotary Drive Motor…………………………………………………………………………………………………….. 6-62
Winch Assembly……………………………………………………………………………………………………………. 6-63
Precautions on the use of Winches……………………………………………………………………………… 6-63
Wire Rope………………………………………………………………………………………………………………… 6-63
Wedge Sockets…………………………………………………………………………………………………………. 6-65
Grooved Drums…………………………………………………………………………………………………………. 6-65
Plain (Smooth) Drums………………………………………………………………………………………………… 6-66
Drums – Multiple Layers……………………………………………………………………………………………… 6-66
Deck Wrench…………………………………………………………………………………………………………………. 6-68
Deck Wrench…………………………………………………………………………………………………………….. 6-68
H.O.B.O. Wrench……………………………………………………………………………………………………………. 6-69
H.O.B.O Wrench……………………………………………………………………………………………………….. 6-69
Tong Dies…………………………………………………………………………………………………………………. 6-70
Optional Hydraulic Operated Bit Basket – H.O.B.B…………………………………………………………. 6-70
Pipe Positioner………………………………………………………………………………………………………………. 6-71
Pipe Positioner………………………………………………………………………………………………………….. 6-71
Carousel Pipe Rack……………………………………………………………………………………………………….. 6-72
Carousel Pipe Rack……………………………………………………………………………………………………. 6-72
Chain Drive – Adjustment / Replace……………………………………………………………………………… 6-72
Pipe Rack Bearings – Replace…………………………………………………………………………………….. 6-73
Carousel Top Tube Bearing – Replace………………………………………………………………………….. 6-74
Carousel Lower Bearing – Replace………………………………………………………………………………. 6-76
Upper Pivot Support Bearing……………………………………………………………………………………….. 6-77
Carousel Pivot Support Upper Bearing – Replace………………………………………………………….. 6-78
Pivot Support Pipe Lower Bushing……………………………………………………………………………….. 6-79
Carousel Pivot Support Lower Bearing – Replace………………………………………………………….. 6-80
Mid Point Carousel Pivot Support………………………………………………………………………………… 6-81
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Bucyrus International, Inc.®
April, 10 Version 1 Int-13 SKF Introduction
Contents
Top Sub Saver……………………………………………………………………………………………………………….. 6-82
Replacement Procedure……………………………………………………………………………………………… 6-82
Notes…………………………………………………………………………………………………………………………….. 6-83
Section 7 – Hydraulic Systems………………………………………………… 7-1
Section 7 Contents………………………………………………………………………………………………………….. 7-3
Hydraulic Symbols………………………………………………………………………………………………………….. 7-7
Hydraulic Symbols……………………………………………………………………………………………………….. 7-7
Hydraulic Tank………………………………………………………………………………………………………………… 7-9
Hydraulic Tank…………………………………………………………………………………………………………….. 7-9
Hydraulic System………………………………………………………………………………………………………. 7-10
Pressure Setting Sequence……………………………………………………………………………………………..7-11
Pressure Setting Sequence…………………………………………………………………………………………..7-11
Hydraulic System………………………………………………………………………………………………………..7-11
Main Return and Case Drain Filter………………………………………………………………………………….. 7-12
Routine Maintenance…………………………………………………………………………………………………. 7-13
Changing Filter Elements……………………………………………………………………………………………. 7-13
Main Hydraulic Pumps…………………………………………………………………………………………………… 7-14
Pump Identification…………………………………………………………………………………………………….. 7-14
Right Track / Left Track / Rotation Pumps………………………………………………………………………. 7-15
Break Test Procedure Sk Infinity Series Drills……………………………………………………………….. 7-15
Setting Procedure………………………………………………………………………………………………………. 7-15
Technical Data…………………………………………………………………………………………………………… 7-17
Main Pump Adjustments……………………………………………………………………………………………… 7-18
Charge Pressure, High Pressure, P.O.R and Zero Position settings…………………………………. 7-19
Set Charge Pressure – 320psi (22 bar)…………………………………………………………………………. 7-19
Linde HPR-02 Self-Regulating Pumps………………………………………………………………………….. 7-20
Cross section of Single Pump……………………………………………………………………………………… 7-22
Operational Parameters……………………………………………………………………………………………… 7-24
Linde HPR-02 Pump Schematic…………………………………………………………………………………… 7-25
Controls……………………………………………………………………………………………………………………. 7-26
Dimensions……………………………………………………………………………………………………………….. 7-29
Charge Pumps………………………………………………………………………………………………………….. 7-30
Setting Linde HPR-02 Main pumps – Neutral Setting…………………………………………………….. 7-31
Setting Linde HPR-02 Main pumps – Pressure Settings…………………………………………………. 7-32
Setting Linde HPR-02 Main pumps – Pre-setup Checks…………………………………………………. 7-33
Main Pumps Linde HPR-02…………………………………………………………………………………………. 7-34
Charge Circuit……………………………………………………………………………………………………………….. 7-35
Charge Circuit Schematic……………………………………………………………………………………………. 7-35
Charge Circuit…………………………………………………………………………………………………………… 7-36
Routine Maintenance…………………………………………………………………………………………………. 7-37
Changing Filter Elements……………………………………………………………………………………………. 7-38
Main Pumps Circuit……………………………………………………………………………………………………….. 7-39
Main Pumps Circuit……………………………………………………………………………………………………. 7-39
Loop Filters…………………………………………………………………………………………………………………… 7-40
Loop Filters……………………………………………………………………………………………………………….. 7-40
BI620416
Bucyrus International, Inc.®
SKF Introduction Int-14 April, 10 Version 1
Contents
Routine Maintenance…………………………………………………………………………………………………. 7-40
Loop Filter Cross Section……………………………………………………………………………………………. 7-41
Filter Assembly Loop………………………………………………………………………………………………….. 7-42
Changing Filter Elements……………………………………………………………………………………………. 7-43
Diverter Valve………………………………………………………………………………………………………………… 7-44
Closed Loop Pump Circuit…………………………………………………………………………………………… 7-44
Operation………………………………………………………………………………………………………………….. 7-44
Diverter Valve……………………………………………………………………………………………………………. 7-44
Rotation Circuit……………………………………………………………………………………………………………… 7-45
Rotation / Tram Motor Circuit Schematic……………………………………………………………………….. 7-45
Rotation Circuit………………………………………………………………………………………………………….. 7-46
Rotary Drive Gearbox Motor…………………………………………………………………………………………… 7-47
Variable Displacement Motor AA6M……………………………………………………………………………… 7-47
Tram Circuit…………………………………………………………………………………………………………………… 7-61
Tram Circuit………………………………………………………………………………………………………………. 7-61
Basic Rotation Circuit…………………………………………………………………………………………………. 7-62
Tram Circuit Schematic………………………………………………………………………………………………. 7-63
Counterbalance Valves………………………………………………………………………………………………….. 7-64
Counterbalance Valve Adjustment……………………………………………………………………………….. 7-64
Pilot Control Manifold……………………………………………………………………………………………………. 7-65
Pilot Control Manifold…………………………………………………………………………………………………. 7-65
Pilot Control Manifold Assembly…………………………………………………………………………………… 7-66
Control Valve Assembly………………………………………………………………………………………………. 7-67
Torque Control…………………………………………………………………………………………………………… 7-74
Parts List………………………………………………………………………………………………………………….. 7-75
Proportional Pulldown………………………………………………………………………………………………… 7-76
Proportional Valve Set Up…………………………………………………………………………………………… 7-77
Auto Pulldown Card……………………………………………………………………………………………………. 7-77
Auxiliary Pump Circuit…………………………………………………………………………………………………… 7-78
Spools……………………………………………………………………………………………………………………… 7-78
Electro – Hydraulic Kit (24V DC)………………………………………………………………………………….. 7-78
Feed and Auxiliary Pump Circuit………………………………………………………………………………….. 7-80
Auxiliary Pump Circuit Schematic………………………………………………………………………………… 7-81
Feed and Auxiliary Functions Pump……………………………………………………………………………… 7-82
Pump Replacement – Start Up…………………………………………………………………………………….. 7-82
Jack Control and Mast Elevating Circuit…………………………………………………………………………. 7-84
Jack Control and Mast Elevating Circuit Schematic………………………………………………………… 7-84
Jack Control and Mast Elevating Circuit………………………………………………………………………… 7-85
Levelling Jack Cylinders………………………………………………………………………………………………… 7-86
Jack Leg Cylinder………………………………………………………………………………………………………. 7-86
Counterbalance Valve Test Procedure………………………………………………………………………….. 7-86
Mast Elevating Cylinders……………………………………………………………………………………………….. 7-87
Internal Counterbalance Valve…………………………………………………………………………………….. 7-87
Auxiliary Circuit…………………………………………………………………………………………………………….. 7-89
Auxiliary Functions Circuit…………………………………………………………………………………………… 7-89
4WE6 Auxiliary Valves………………………………………………………………………………………………… 7-91
Exploded View of 4WE6……………………………………………………………………………………………… 7-93
BI620416
Bucyrus International, Inc.®
April, 10 Version 1 Int-15 SKF Introduction
Contents
Hydraulic Operated Breakout Wrench…………………………………………………………………………….. 7-94
H.O.B.O Wrench……………………………………………………………………………………………………….. 7-94
Setting of H.O.B.O Sequence Valves……………………………………………………………………………. 7-95
H.O.B.O Float Valve…………………………………………………………………………………………………… 7-95
Cooler Fan Circuit………………………………………………………………………………………………………….. 7-96
Cooler Fan Circuit……………………………………………………………………………………………………… 7-96
Setting Cooler Fan Speed…………………………………………………………………………………………… 7-96
Basic Cooler Fan Circuit……………………………………………………………………………………………… 7-98
Cooler Fan Motor…………………………………………………………………………………………………………… 7-99
Hydraulic Motor…………………………………………………………………………………………………………. 7-99
Cooler Fan Motor Assembly………………………………………………………………………………………. 7-101
Hydraulic Feed Circuit………………………………………………………………………………………………….. 7-103
Hydraulic Feed Circuit………………………………………………………………………………………………. 7-103
Hoist and Pulldown Control………………………………………………………………………………………….. 7-105
M-22 Valve……………………………………………………………………………………………………………… 7-105
Feed Valve Assembly…………………………………………………………………………………………………… 7-107
Feed Valve Assembly……………………………………………………………………………………………….. 7-107
Control Valve Assembly……………………………………………………………………………………………….. 7-109
Technical Data…………………………………………………………………………………………………………. 7-109
Hydraulic Cylinder Repair……………………………………………………………………………………………… 7-111
Hydraulic Cylinders……………………………………………………………………………………………………7-111
General Information……………………………………………………………………………………………………7-112
H Head…………………………………………………………………………………………………………………….7-114
N Head…………………………………………………………………………………………………………………….7-115
Z Head……………………………………………………………………………………………………………………..7-116
Z Head (Two Piece)……………………………………………………………………………………………………7-117
K Head…………………………………………………………………………………………………………………….7-118
M Head…………………………………………………………………………………………………………………….7-119
Z Piston………………………………………………………………………………………………………………….. 7-120
Z Piston (Threaded)…………………………………………………………………………………………………. 7-121
H and K Piston………………………………………………………………………………………………………… 7-122
M Piston…………………………………………………………………………………………………………………. 7-123
N Piston………………………………………………………………………………………………………………….. 7-126
Notes…………………………………………………………………………………………………………………………… 7-127
Section 8 – Electrical Components…………………………………………..8-1
Section 8 Contents………………………………………………………………………………………………………….. 8-3
Electrical Locator…………………………………………………………………………………………………………….. 8-5
Electrical Component Location………………………………………………………………………………………. 8-5
Jump Starting………………………………………………………………………………………………………………….. 8-8
Jump Starting……………………………………………………………………………………………………………… 8-8
Batteries……………………………………………………………………………………………………………………….. 8-10
Batteries…………………………………………………………………………………………………………………… 8-10
Welding Precautions……………………………………………………………………………………………………….8-11
Welding Precautions……………………………………………………………………………………………………8-11
BI620416
Bucyrus International, Inc.®
SKF Introduction Int-16 April, 10 Version 1
Contents
Electrical Components…………………………………………………………………………………………………… 8-12
Electrical Circuits……………………………………………………………………………………………………….. 8-12
Transducers……………………………………………………………………………………………………………… 8-12
EP Levers…………………………………………………………………………………………………………………. 8-13
Joystick Adjustments………………………………………………………………………………………………….. 8-14
Vigilante Guide………………………………………………………………………………………………………………. 8-16
Important Information…………………………………………………………………………………………………. 8-16
PLC…………………………………………………………………………………………………………………………. 8-17
Touchscreen……………………………………………………………………………………………………………… 8-20
Laser Depth System…………………………………………………………………………………………………… 8-21
Start Up and Shutdown………………………………………………………………………………………………. 8-24
Hydraulic Function Enable………………………………………………………………………………………….. 8-24
Alarms……………………………………………………………………………………………………………………… 8-24
Solenoid Control………………………………………………………………………………………………………… 8-25
Auto Lube…………………………………………………………………………………………………………………. 8-27
Gauges…………………………………………………………………………………………………………………….. 8-27
Level Switches………………………………………………………………………………………………………….. 8-30
Dust Suppression………………………………………………………………………………………………………. 8-30
Acknowledgements……………………………………………………………………………………………………. 8-31
Disclaimers……………………………………………………………………………………………………………….. 8-31
Notes…………………………………………………………………………………………………………………………….. 8-32
N.B: For further information on specific electronic components, please refer to
Vendor Documents in table of contents on Service Manual CD.
Section 9 – Lubrication and Preventive Maintenance………………..9-1
Section 9 Contents………………………………………………………………………………………………………….. 9-3
Central Lube System……………………………………………………………………………………………………….. 9-5
Auto Lube Basic Operation…………………………………………………………………………………………… 9-5
Central Lube Tank Assembly…………………………………………………………………………………………. 9-6
Auto Lube Grease Pump………………………………………………………………………………………………. 9-7
Auto Lube Tube Pump………………………………………………………………………………………………… 9-12
Graco Vent Valve……………………………………………………………………………………………………….. 9-16
Central Lube System Circuit………………………………………………………………………………………… 9-17
Basic Operational Principles of Auto Lube Injectors………………………………………………………… 9-18
SL-V and SL-V XL Injectors………………………………………………………………………………………… 9-18
SL-1 and Sl-11 Injectors……………………………………………………………………………………………… 9-19
SL-32 Injectors………………………………………………………………………………………………………….. 9-20
Typical Grease System Circuit…………………………………………………………………………………….. 9-21
First 50 Hours Service………………………………………………………………………………………………… 9-22
Lube Faults / Operation………………………………………………………………………………………………. 9-23
Auto Lube Timer………………………………………………………………………………………………………… 9-24
Lube Pressure Screen………………………………………………………………………………………………… 9-24
Air Service Units……………………………………………………………………………………………………………. 9-25
Filter Regulator………………………………………………………………………………………………………….. 9-25
Air Line Oiler……………………………………………………………………………………………………………… 9-26
Soft Start Dump Valve………………………………………………………………………………………………… 9-27
Air Service Unit………………………………………………………………………………………………………….. 9-28
BI620416
Bucyrus International, Inc.®
April, 10 Version 1 Int-17 SKF Introduction
Contents
Pipe Thread Lubricator………………………………………………………………………………………………….. 9-29
Air Operator Pipe Thread Pump…………………………………………………………………………………… 9-29
Filter Locator…………………………………………………………………………………………………………………. 9-37
Filter Locator Assembly………………………………………………………………………………………………. 9-37
Lubrication and Preventive Maintenance………………………………………………………………………… 9-38
General Lubrication……………………………………………………………………………………………………. 9-38
Equipment Lubrication………………………………………………………………………………………………… 9-38
Care of Lubrication Points…………………………………………………………………………………………… 9-38
Safety………………………………………………………………………………………………………………………. 9-39
Track Gear………………………………………………………………………………………………………………… 9-40
Engine Maintenance…………………………………………………………………………………………………… 9-41
Air Cleaners………………………………………………………………………………………………………………. 9-42
Air Filter Elements……………………………………………………………………………………………………… 9-42
Alternator Maintenance………………………………………………………………………………………………. 9-42
Pump Drive and Drive Shaft Maintenance…………………………………………………………………….. 9-43
Compressor Maintenance…………………………………………………………………………………………… 9-43
Cooler Packs…………………………………………………………………………………………………………….. 9-43
A-frame and Pivot Point Maintenance…………………………………………………………………………… 9-45
Pull Down and Hoist Ropes and Sheaves Maintenance………………………………………………….. 9-45
Rotary Head Maintenance…………………………………………………………………………………………… 9-45
Hydraulic System Maintenance……………………………………………………………………………………. 9-47
Hydraulic Maintenance……………………………………………………………………………………………….. 9-47
Water Pump Maintenance…………………………………………………………………………………………… 9-47
Cab Maintenance………………………………………………………………………………………………………. 9-47
Air Conditioner Maintenance……………………………………………………………………………………….. 9-49
Battery Maintenance………………………………………………………………………………………………….. 9-49
Lubrication System Maintenance…………………………………………………………………………………. 9-49
Fire Suppression Maintenance…………………………………………………………………………………….. 9-49
Drill Folding Stairway – Inspection Requirements…………………………………………………………… 9-51
Weld Inspection Schedule……………………………………………………………………………………………… 9-52
Weld Inspection Schedule SK Series……………………………………………………………………………. 9-52
Track and Sprocket Inspection……………………………………………………………………………………….. 9-53
Track Inspection and Wear Limit Guide………………………………………………………………………… 9-53
Sprocket Wear Patterns……………………………………………………………………………………………… 9-58
Lubrication Recommendations………………………………………………………………………………………. 9-64
Lubrication Recommendations…………………………………………………………………………………….. 9-64
Lubrication and Maintenance Chart – 250hr……………………………………………………………………. 9-65
Lubrication and Maintenance Chart – 500hr……………………………………………………………………. 9-75
Lubrication and Maintenance Chart – 1000hr………………………………………………………………….. 9-86
Lubrication and Maintenance Chart – 2000hr………………………………………………………………….. 9-97
Lubricant Specifications………………………………………………………………………………………………. 9-109
Hydraulic System…………………………………………………………………………………………………….. 9-109
Hydraulic Tank Capacity……………………………………………………………………………………………. 9-109
Compressor Lubrication……………………………………………………………………………………………..9-110
Compressor Lubricant Specifications……………………………………………………………………………9-110
Lubricating Grease…………………………………………………………………………………………………….9-111
BI620416
Bucyrus International, Inc.®
SKF Introduction Int-18 April, 10 Version 1
Contents
Gear Lubricant…………………………………………………………………………………………………………..9-111
Scheduled Oil Sampling Analysis…………………………………………………………………………………9-111
Torque Values for Split Flange Connections…………………………………………………………………..9-112
Torque Values for Split Flange Connections………………………………………………………………….9-112
Procedure No. 1-87 Revision A……………………………………………………………………………………9-114
Notes…………………………………………………………………………………………………………………………….9-115

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