PDF Service Manual Cat Bucyrus Terex SKS-W Infinity Blasthole Drill - 4 MB
This service manual is the complete technical guide for the Cat Bucyrus Terex SKS-W Infinity Blasthole Drill (SN 1A66K53).
It provides in-depth procedures for maintenance, troubleshooting, and repair of this specialized mining equipment.
Technicians will rely on this manual for detailed specifications and step-by-step instructions to ensure the drill operates safely and effectively.
This document is critical for minimizing downtime.
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BI620445
© Bucyrus
All Rights Reserved
BUCYRUS R
Technical Manual
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BI620445
Contents
Weld Inspection Schedule.............................................................................................................. 6-6
Mast Inspection........................................................................................................................... 6-6
Mast Assembly................................................................................................................................. 6-7
Mast Assembly 10m.................................................................................................................... 6-7
Mast Weldment........................................................................................................................... 6-8
Mast Pivot.................................................................................................................................... 6-8
Mast Locking............................................................................................................................... 6-8
Hoist / Pulldown Cylinder............................................................................................................... 6-9
Hoist / Pulldown Cylinder Parts List............................................................................................ 6-9
Removal From Mast Assembly.................................................................................................. 6-10
Repair.........................................................................................................................................6-11
Installation..................................................................................................................................6-11
Hoist / Pulldown Cable Adjustment............................................................................................. 6-13
Hoist / Pulldown Cable Adjustment........................................................................................... 6-13
Hoist / Pulldown Cable Replacement........................................................................................ 6-15
Rotary Drive................................................................................................................................... 6-17
Rotary Head Assembly and Parts List....................................................................................... 6-17
Rotary Head Guide Alignment................................................................................................... 6-18
Rotary Head – Drive System..................................................................................................... 6-19
Rotary Drive – Removal from Mast........................................................................................... 6-20
Rotary Drive – Installation......................................................................................................... 6-20
Rotary Drive Gearbox – Repair................................................................................................. 6-21
Rotary Head Bull Shaft Bearing Nut.......................................................................................... 6-22
Air Swivel................................................................................................................................... 6-23
Winch Assembly............................................................................................................................ 6-24
Precautions on the use of Winches.......................................................................................... 6-24
Wire Rope................................................................................................................................. 6-24
Wedge Sockets......................................................................................................................... 6-26
Grooved Drums......................................................................................................................... 6-26
Plain (Smooth) Drums............................................................................................................... 6-27
Drums – Multiple Layers............................................................................................................ 6-27
Winch Assembly Service........................................................................................................... 6-28
BG8A and BG8B Hydraulic Winch Manual................................................................................ 6-29
Forward............................................................................................................................... 6-30
Explanation of Model Number............................................................................................ 6-30
Theory of Operation............................................................................................................ 6-31
Winch Installation................................................................................................................ 6-33
Wire Rope Installation......................................................................................................... 6-34
Preventative Maintenance.................................................................................................. 6-35
071 Motor............................................................................................................................ 6-36
Trouble Shooting................................................................................................................. 6-37
Disassembly of Winch......................................................................................................... 6-41
Planetary Carrier Service.................................................................................................... 6-43
Motor Support Brake Cylinder Service............................................................................... 6-45
Brake Clutch Service.......................................................................................................... 6-49
Winch Assembly................................................................................................................. 6-51
Int-10 SKS-W Introduction
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Notes
Int-20 SKS-W Introduction
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Safety
Defines the area captured by
closed circuit cameras (if fitted)
Shaded area defines the operators
general line of sight when in the
seated position
• Always check blind spots prior to propelling.
• Do not carry out any drilling activity on a bench until it has been examined for misfires.
• Do not drill a hole so that any portion of the hole is closer than 6 metres to a hole containing
explosives. Site rules may stipulate further distances.
• Ensure adequate ventilation when running the engine in an enclosed area. Exhaust gases contain
carbon monoxide, a deadly poison which is colourless and odourless.
• Ensure the drill pipes are secure in the carousel before raising or lowering the mast.
• Before lowering the mast, do make sure the carousel is rotated, locked in the non-pipe-loading
centre position to ensure pipes are secured so they cannot possibly slide back and fall out of the
carousel. Then swing the carousel in towards the centre of the mast.
• Do make sure dust is suppressed whilst drilling using either the dust collector or water injection.
• Do not climb the ladder to the operator cabin roof whilst the machine is running and always
ensure secure footing.
• Do not under any circumstance climb the ladder giving access to the mast without wearing the
appropriate safety harness. Only ever perform service work on the mast wearing approved fall
arrest equipment.
• Do not travel on steep inclines, soft or unstable ground or close to unsupported excavations.
• Do not propel the machine with the mast up.
1-10 SKS-W Safety
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Graphic Symbol Legend
Hydraulically Operated Breakout Hydraulically Operated Breakout
Jack – FRONT
Wrench (HOBO) – CLAMP Wrench (HOBO) – SWING
Ignition – ON Ignition - OFF
Jack – LEFT REAR
Winch – RAISES HOOK Hoist/Pulldown – RAISE and LOWER Jack – RIGHT REAR
Winch – LOWERS HOOK Main Air Jack – DOWN
Fuel Level Mast – LOWER Jack – UP
Hydraulic System Pressure Mast – RAISE Mast Lock
2-6 SKS-W Operators Cab / Controls
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BI620445
Operator
OperatorsControl PanelInstrument
and
Cab / Controls(optional)Panels
Left Hand Control Panel
24 39 25 38 36 37
DISENGAGE
Not Used
34
REAR ROOF ENGAGE
OUT ON
33
Not Used
IN OFF
MAN AUTO SIDE FRONT
35
NOT USED NOT USED
OFF ON
REVERSE NORM
26 27 28 30 31 32 29
2-16 SKS-W Operators Cab / Controls
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Air Conditioner
Section 2.0 Installation and Commissioning
2.1 Compressor Installation
1. If a special P.T.O. drive pulley is required this should be installed by an experienced tradesman,
taking care not to damage any seals or disturb any gear trains within the P.T.O. drive.
2. The compressor bracket should be designed and manufactured by SIGMA or alternatively,
manufactured by customer to SIGMA specifications. All hardware used to mount the bracket to the
engine should be of the correct grade, size and length to suitably support the bracket. Ensure that
the bracket sits square on the engine and that the mounting bolts are tightened to the correct torque.
3. Check that the belt section of the clutch pulley groove matches with that of the drive pulley.
4. Mount the compressor assembly onto the bracket and check for any interference, between the
compressor and engine, along the full path of the compressor adjustment travel. Correctly align the
compressor clutch groove with the drive pulley groove. If a separate eccentric adjusting pulley is
utilised, ensure that this also is in correct alignment. Shim if necessary.
5. Install belt(s) and tension as required. Check for any possible interference between drive belts and
any engine components during operation. On applications that require long belt runs check for
excessive belt 'whip'.
6. To ensure maximum operator and service personnel safety, wherever possible, guards should be
provided to cover any exposed drive belts and/or pulleys.
7. After running the unit for approximately one hour, re-check the belt tension and adjust accordingly.
8. During commissioning of unit visually check the compressor/bracket assembly for any undue
vibrations through the engine rev. range and also make the compressor 'cut-in' to check the bracket
for any undue flexing under conditions of compressor start-up at full load.
2.1.1 Compressor Selection
Various compressors can be utilised with this system.
MAKE SANDEN TECUMSEH DELCO UNICLA
MODEL SD7H15 HGB1000 UP170
Displacement 161cc 169cc 207c 172
No. of Cylinders 5 2 6 10
Refrigerant Type R134a R134a R134a R134a
Oil Type RL68S RL68S RL68S Unidap 7(PAG)
Oil Capacity 135ml 297 ml 300 ml 150
Rotation Bidirectional Bidirectional Clockwise Bidirectional
Mounting Angle 45o of TDC 45o of TDC N/A 45o of TDC
Max Speed 4000 RPM 6000 RPM 6500 RPM 7000RPM
2.2 Power Supply Connection
Check power supply to unit. Alternator capacity must be sufficient for air conditioners as well as other
accessories; determine if night operation is required.
1. Connect the electrical supply wiring harness to unit and run wiring to clutch and power source
ensuring that it is suitably secured and does not run over hot exhausts, etc.
2-26 SKS-W Operators Cab / Controls
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Air
Air Conditioner
Conditioner
SIGMA COACHAIR GROUP
4.1.2 System
7.1.2OnlySystem
Partially Cools
Only Partially Cools
2-36 SKS-W Operators Cab / Controls
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Air Conditioner
5.5 Performance Curve
Performance Curve
Test Conditions: Dis. Pressure: 1.52MPa (gage)
Suc. Pressure: 0.182MPa (gage)
13 13
12 12
11 11
Capacity Capacity Capacity
10 100 10
9 90 9
Power Consumption (kw)
Volumetic Efficiency (%)
Cooling Capacity (kw)
8 Volumatic 80 Volumatic 8 Volumatic
Efficiency Efficiency Efficiency
7 70 7
6 60 6
5 50 5
4 40 4
Power Consumption Power Consumption Power Consumption
3 30 3
2 20 2
1 10 1
0 0 0
0 1 2 3 0 1 2 3 0 1 2 3
Revolutions (x1000r/min) Revolutions (x1000r/min) Revolutions (x1000r/min)
1. Centre bolt 9. O-ring
2. Armature assembly 10. Oil filler plug
3. Adjusting Shim
4. Snap ring
5. Pulley assembly
6. Screw
7. Field coil
8. Compressor
2-46 SKS-W Operators Cab / Controls
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Levelling Jacks
Levelling Jacks
Levelling Jacks
Detecting Levelling Jack Troubles – Faulty levelling jacks may be detected through inspection,
or through operating difficulties encountered. Refer to Hydraulics in Section 7.
Limit Switch
The Limit Switches send a signal via the Vigilante Control arm is slotted for
length adjustment
that the levelling cylinders are fully retracted to
allow tramming functions to activate. It is imperative
that the Limit switch control arm be adjusted to Limit Switch
strike on the Inner Casing (Fig LJ-2) and not the
Hydraulic cylinder. This is done to prevent damage
should the lower bolt fail or fall out, leaving
the Inner Casing Tube still lowered but having the
Hydraulic cylinder fully retracted/raised.
Levelling Jack Cylinders
Removal
1. Lower jack pad to ground, but do not
Arm length adjusted to
have weight of machine on jacks. strike the inner casing tube
NOT the jack cylinder
2. Shut down machine.
WARNING: Relieve pressure on
Fig. LJ-2 Levelling Jack Cylinder Limit Switch
hydraulic and pneumatic systems
before loosening connections or parts.
3. Remove lower bolt that holds retainer cap/jack pad to cylinder.
4. With hydraulic pressure relieved, disconnect upper fittings to cylinder and clamps.
5. Remove cap screws and cap from top of cylinder outer casing.
6. Hydraulic cylinder may have a lifting eye installed or it will have tapped holes to install a lifting eye.
Using a suitable crane or heavy lifting device lift cylinder out of casing.
Repair
Refer to parts manual for specific cylinder and repair parts. Refer to cylinder repair information in
Section 7 for type of cylinder on machine. The levelling jack cylinder has a 'Z' type head and piston.
Replace
1. Replacement is reverse of removal procedure.
2. Rotate jack pad to align bolt hole with cylinder.
3. Cycle cylinder several times to remove trapped air before putting machine into service.
WARNING: Cylinder must be free from air prior to putting under load.
Lubricating Jack Casings
If jack casings have been cleaned of grease, then a thin coating of grease will need to be applied
manually, this is done by fully extending the levelling jack and applying directly to casing tube. The
central lube system will then maintain adequate lubrication of the casings.
3-8 SKS-W Main Frame Crawlers
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Track Tension Adjustment Track Tension Adjustment
Idler Unit Description
• The idler wheel is filled with oil and the running surfaces are induction hardened for reduction
in wear.
• The sliding block (3) is designed in such a way that no dirt can enter the idler.
• The hydraulic tensioner (4) serves to tighten the track chain when grease is inserted with a
grease gun.
• The nitrogen tensioner (5) is pressurised at the factory and normally requires no
other maintenance.
WARNING: HIGH PRESSURE The nitrogen tensioner is under high pressure. Bleed
off all pressure before any service work is performed on the unit. Follow instructions
in this section. It is recommended that service work on the nitrogen tensioner be
done only by factory authorised service agents. If service work is performed by
non-factory authorised personnel, all liability and/or damage is assumed by party(ies)
performing the work. If unit is disassembled, always discard all fasteners and replace
with new ones.
WARNING: Grease in the hydraulic tensioner is under high pressure. Grease coming out
of the relief valve at the back of the hydraulic tensioner is under high pressure and can
penetrate the body causing personal injury or death. When loosening the tension on the
track, loosen the relief valve only one turn. DO NOT visually inspect the relief valve to
see if grease is being released from the track adjuster. Instead, watch the track to see if
it loosens. If the track does not loosen after opening the relief valve, move the machine
forward and backward to release the tension.
3-18 SKS-W Main Frame Crawlers
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Track Shoes Installation Main Frame / Crawlers
When assembling the track shoes in the field, this method must be used because the final torque is not
done with a calibrated torque wrench and although the deviation may be small, the tightening of a third
of a turn more, gives the necessary clamping force independent for the required friction factor.
Track Shoe – Retightening
DO NOT merely retorque the bolts in the field. This would lead to failure of the joint due to the altered
friction factor and a reduced preload of the bolts.
The CORRECT METHOD of retightening the bolts, is to loosen the bolts until they turn freely. Now
torque the bolts using the 'torque turn' method described above.
NOTE: This can only be done once and only after a short time of machine operation
(approximately 50 hours). After extended operation, loose bolts and nuts must be replaced
with new ones for safety reasons.
3-28 SKS-W Main Frame Crawlers
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Final Drive Unit Final Drive Assembly
Final Drive Assembly
Fig. 3-51 Final Drive Assembly
3-38 SKS-W Main Frame Crawlers
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Track and Support Rollers Track and Support Rollers
Track and Support Roller – Assembly
9
2
7
9 4
Fig. TSR-6 Bushing – Install Fig. TSR-7 Seals – Install
1. Clean all parts thoroughly and press the bushings 2. Place the seals (4) in position in the roller body
(9) into the roller body so that the oil grooves in the (7) and brackets (2), (fig. TSR-7). Be sure the
bushing are aligned with the oil fill hole (fig. TSR-6). seal lips face away from each other.
NOTE: If reusing the old seals, be sure to mark them, so they go back into the same bore they
came out of. Otherwise they may not seal properly.
2
6
5
Fig. TSR-8. Shaft – Install Fig. TSR-9 Shaft – Install Into Roller Body
3. Install o rings (5) onto shaft (6). Install shaft 4. Align hole in shaft (6) with hole in bracket (2),
into one bracket (2) making sure the oil groove place a wood block under bracket and install
(A) faces the same direction as the mounting roll pin (3). Push assembled shaft into roller
surface (B) of the bracket (fig. TSR-8). body (fig. TSR-9).
NOTE: Place a block of wood under the bracket when driving in roll pin to avoid damage to the
seal retainer.
6. Install other bracket (2) onto shaft, align holes
as in step 4, place a wood block under bracket
3 and drive in roll pin (3). Fig. TSR-10.
10
Fig. TSR-10 Roll Pin – Install
3-48 SKS-W Main Frame Crawlers
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Track and Sprocket Inspection
Sprocket Wear Patterns (cont.)
Wear of Tooth Tip
Wear of tooth tip.
Causes:
• Due to internal joint wear, the pitch is increased
and the bushings get closer to the tooth tip. In
some instances the bushings jump over the tip
of the tooth.
• On very cohesive soils, the tooth bottom is
packed with soils causing a pitch mismatch.
This causes the bushing to ride high on the
tooth profile.
• New sprockets run with used tracks causes a
pitch mismatch. The larger pitch of the used
track is transferred to the new sprocket by an increased wear rate.
• During reverse travel, with loose tracks, a reduced angle of contact between the bushing and
sprocket causes the bushing to ride high on the tooth profile.
Effects:
• Track chain tends to jump over the teeth.
• If the tooth tip is extremely worn, the track can not support the forces and may slip over the bushing
and reducing traction. Safe operation on slopes is no longer assured.
Remedies:
• If running in cohesive soils use sprockets with mud reliefs.
• Use track shoes with centre mud holes for better cleaning of the track and better engagement
between sprockets and bushing.
3-58 SKS-W Main Frame Crawlers
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Auxiliary Crane
Hydraulic Fluids
6.1-6 Hydraulic fluids
For the selection of hydraulic fluids you should get in touch with your service partner.
HLP / ISO hydraulic fluids wth the following properties should be used:
• favourable viscosity/temperature behaviour.
• good thermal and mechanical loading properties.
• extensive resistance to ageing.
• good corrosion protection.
• adequate cold flowability.
• adequate lubrication effect in the marginal lubrication area.
• good air release properties.
• excellent foam behaviour.
• neutrality in contact with seals and hydraulic hoses.
As the viscosity of hydraulic fluids changes considerably through fluctuations in temperature,
compromises cannot be avoided in their selection. For your PALFINGER crane the following limit
values apply:
Operation limits
Recommended range
ISO standard temperature Temperatur °C
• High temperatur range: 10 cSt
• Cold start limit: 1000 cSt
• Purity class: 15/12 (to ISO 4406)
3-68 SKS-W Main Frame Crawlers
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Caterpillar
Caterpillar C27
C27 Engine
Engine
Caterpillar C27 Engine
The SKS-W has a turbocharged and after cooled Caterpillar C27 twelve cylinder diesel engine
producing 800Hp at 2100rpm.
Engine Service Procedures
Lubrication requirements, fluid levels, and general service requirements are covered in Section 9. Refer
to the engine manufacturer’s manual on the specific engine for more detailed service requirements.
Fig. 4-2 Caterpillar C27 Engine
Engine Oil Pressure Switches
• Oil pressure gauge sender – this measures engine oil
pressure. This sender provides a reading of the engine
oil pressure to the gauge in the cab. The sender has no
visual or audible alarm.
• Engine Oil Pressure switch – This switch closes when
adequate Engine Oil pressure is reached upon start- up.
If the Engine Oil pressure falls below 15psi, the switch
will open and flag an alarm on the Vigilante.
2
NOTE: The two switches are mounted on a tee which 1
screws on the engine oil filter housing on the left hand
side of the engine.
Fig. 4-3 Engine Switches
1. Oil pressure gauge sender
2. Oil Pressure switch
4-6 SKS-W Engine / Drive Train / Compressor
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Pump Drive Gearbox Pump Drive Gearbox
Pump Drive Gearbox
16 17 12
11