Cat Bucyrus Terex SKSS-13 Infinity Blasthole Drill Service Manual SN 1S67T07 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus Terex SKSS-13 Infinity Blasthole Drill Service Manual SN 1S67T07 – PDF DOWNLOAD
Language : English
Pages : 779
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
Cat Bucyrus Terex SKSS-13 Infinity Blasthole Drill Service Manual SN 1S67T07 – PDF DOWNLOAD
Safety Information:
- This manual is furnished with your Innity 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 sufciently in this manual, the matter should be
referred to manufacturer. - The descriptions and specications 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 specic requirements, government regulations, required precautions and any work
hazards which may exist. You must make these known to all personnel working with the equipment or
in the area, so that all may take the necessary and required safety precautions. Keep all children,
visitors, and untrained personnel away from the equipment. It is also your responsibility to
operate your equipment with skill, good judgment, and caution. Following recognized safety
procedures will help you avoid accidents. Failure to heed these instructions can result in property
damage, serious injury or death.
TABLE OF CONTENTS:
Cat Bucyrus Terex SKSS-13 Infinity Blasthole Drill Service Manual SN 1S67T07 – PDF DOWNLOAD
SKSS-13_T07 Service Manual.pdf................................................... 0 Introduction................................................................. 3 Safety Information....................................................... 3 Parts Ordering and Product Support....................................... 4 Table of Contents........................................................ 5 General Locator ......................................................... 17 Section 1 - Safety .......................................................... 20 Section 2 - Operator's Cab / Controls........................................ 32 Contents................................................................. 34 Graphic Symbol Legend.................................................... 35 Warning Decals........................................................... 39 Operators Controls and Indicators........................................ 41 Control Panels....................................................... 41 Right Hand Control Panel................................................. 42 Instrument Panel and Circuit Breakers.................................... 43 Circuit Breakers..................................................... 43 Light Switches....................................................... 44 Instrument Panel..................................................... 44 System Pressure Guage Panel.............................................. 45 Left Hand Control Panel.................................................. 47 Air Conditioner.......................................................... 53 T8 Series Split System Air Conditioning Manual....................... 53 Section 3 - Main Frame / Crawlers............................................ 84 Contents................................................................. 86 Main Frame Repair - General.............................................. 88 Main Frame Repair.................................................... 88 Leveling Jacks........................................................... 89 Leveling Jacks....................................................... 89 Leveling Jack Cylinders.............................................. 90 Mast Elevating Cylinders................................................. 91 Mast Elevating Cylinders............................................. 92 Remove............................................................... 93 Repair............................................................... 93 Replace.............................................................. 93 Crawler Assembly......................................................... 94 Crawler Component Repair............................................. 95 Metric Bolt Torque Specifications........................................ 96 Track Maintenance........................................................ 97 Before Operating the Machine......................................... 97 General Maintenance.................................................. 97 Track Tension Adjustment................................................. 98 Hydraulic Tensioner.................................................. 99 Description..........................................................100 Nitrogen Tensioner...................................................101 Hydraulic Tensioner......................................................102 Repair...............................................................102 Nitrogen Tensioner Assembly..............................................103 Nitrogen Tensioner - Fitting Instructions................................104 Nitrogen Tensioner - Pressure Check..................................106 Nitrogen Tensioner - Pressure Release................................106 Track Chain - Separate...................................................107 Track Chain - Repair.....................................................108 Track Link - Repair & Replace........................................108 Track Link - Description.............................................109 Track Shoes Installation.................................................110 Track Link Position..................................................110 Track Shoe - Mounting to Tracsk Chain................................111 Track Shoe Bolt Torque (Direct Torque Method)............................112 Track Shoe Bolt Torque (Torque Turn Method)..............................113 Track Chain and Shoe Installation........................................114 Track Chain with Shoes...............................................114 Track Chain & Shoe - Assembly & Installation.........................114 Final Drive..............................................................116 Final Drive - General Description....................................116 Final Drive Unit Removal.................................................117 Removal from Track Frame.............................................117 Final Drive Unit Installation............................................118 Installation into Track Frame........................................118 Final Drive Maintenance..................................................119 Oil Check / Change...................................................119 Final Drive Oil..........................................................120 Specifications.......................................................120 Recommended Oil......................................................120 Final Drive Assembly.....................................................121 Parking Brake - Description..........................................144 Final Drive - Disconnect & Parking Brake.................................145 Towing Procedure - Gear Drive Disconnect.............................146 Parking Brake - Removal & Installation...............................146 Idler Unit Assembly......................................................147 Idler Unit - Assembly................................................149 Idler Unit Removal.......................................................153 Idler Unit - Removal.................................................153 Track and Support Rollers................................................155 General Description..................................................155 Track Roller - Removal & Disassembly.................................157 Track and Support Roller - Assembly..................................159 Track and Support Roller - Test and Install..........................160 Auxiliary Crane..........................................................162 Hydraulic Crane (Auxiliary Crane)....................................162 Load Lift Capacities.................................................162 Maintenance..........................................................163 Section 4 - Engine / Drive Train / Compressor................................164 Contents.................................................................166 Power Group Locator......................................................169 Cummins Engine...........................................................170 Engine Fuel System...................................................171 Construction.........................................................172 Combo Fuel Filter Head & Pump Manifold...............................173 FS1006 Fuel Filter with Water Separator..............................173 Fuel Manifold with Integrated FSO Valve..............................174 Fuel Connections.....................................................174 Pre Filters..........................................................175 Wiring with EFS Power Relay..........................................175 Pressure and Temperature Sensors.....................................175 Operation............................................................176 QST30 Electric Fuel Supply System....................................177 Oil Reserve Systems..................................................179 Engine Oil Reserve System (Basic Circuit)............................179 LED Monitor Readings.................................................180 Adjustment of Running Oil Level......................................180 Oil Reserve Basic Circuit............................................181 Oil Pressure Switch..................................................181 Oil Reserve System...................................................181 Troubleshooting......................................................182 Maintenance..........................................................182 Engine and Compressor Air Cleaner........................................183 Engine and Compressor Air Cleaner Service............................184 Compressor Assembly......................................................187 Flexible Drive Coupling..................................................188 Flexible Drive Coupling Service......................................188 Pump Drive...............................................................190 Pump Identification..................................................190 Pump Drive Assembly - Removal and Replacement........................191 Pump Drive Gearbox.......................................................192 Pump Drive Gearbox Repair............................................193 3" Input Shaft Assembly..............................................195 Hydraulic Pump...........................................................196 Hydraulic Pumps - Removal and Replacement............................196 Compressor Installation..................................................197 Compressor Drive Coupling............................................197 Compressor Installation..............................................199 Compressor Drive Coupling - Removal and Replacement..................201 Compressor Shaft Seal....................................................202 Compressor Shaft Seal................................................202 Low Pressure Compressosr.................................................205 Safety...............................................................205 Description..........................................................208 Compressed Air Functions.............................................208 Compressor Oil Circuit...................................................212 Diagram Legend.......................................................212 Compressor Oil Circuit - COLD........................................213 Compressor Oil Circuit - HOT.........................................214 Compressor Oil Circuit - Shut Down...................................215 Compressor Air Circuits - 2400cfm @ 100psi...............................216 Diagram Legend.......................................................218 Shutdown.............................................................219 Start Up.............................................................220 Run Loaded...........................................................221 Drilling Air On......................................................222 Compressor Functional Description........................................223 Compressor Operation.....................................................225 Operation............................................................225 Compressor Maintenance...................................................227 General Maintenance..................................................227 Discharge Check Valve................................................229 Compressor Receiver Tank Assembly....................................230 Separator Elements...................................................232 Separator Elements - Remove & Replace................................233 Scavenge Line........................................................234 Compressor Discharge Temperature Gauge, Switch and Sender............235 Minimum Pressure Valve...............................................236 Minimum Pressure / Check Valve Maintenance...........................236 Thermal Bypass Valve.................................................237 Thermal Bypass Valve Maintenance.....................................238 Oil Stop Valve.......................................................239 Compressor Fluid Filter..............................................241 Changing Filter Elements.............................................242 Bearing Oil Filter...................................................243 Compressor Inlet Valve Control System................................244 Compressor Inlet Valve Control System................................245 Relieving Regulators.................................................246 System Blowdown Valve................................................249 Running Blowdown Valve...............................................250 Running Blowdown Maintenance.........................................251 Moisture Separator Maintenance.......................................252 Auxiliary Regulators.................................................253 Auxiliary Regulator Maintenance......................................254 Troubleshooting......................................................257 Aluminum Tube Air to Oil Cooler..........................................261 Compressor Oil Cooler................................................261 Radiator Cooler..........................................................262 Radiator Hydraulic Oil Cooler Assembly...............................262 Radiator / Oil Cooler Repair.........................................271 Section 5 - Dust Control System..............................................278 Contents.................................................................280 Dust Control System......................................................281 Dust Control Systems.................................................281 Dust Collector.......................................................282 Dust Collector Assembly..............................................286 Water Injection..........................................................290 Water Tanks..........................................................290 Water Tank Top up Soleniod Valve.....................................291 Water Injection Relief Valve.........................................293 Water Injection Control..............................................294 Water Injection Basic Circuit........................................296 Water Pump...............................................................297 Pump Specifications..................................................297 Servicing Instructions...............................................297 Parts List...........................................................298 Replacing Piston Cup Seals...........................................299 Replacing Suction and Discharge Valves...............................300 Replacing Power End Bearings.........................................301 Servicing the Wrist Pin Bearings.....................................302 Fastener Torque Requirements.........................................302 Recommended Lubricants...............................................303 Water Pump Motor Repair..............................................303 Water Injection Hydraulic Control Valve Repair.......................303 Water Pump Drive Coupling............................................303 Level and Flow Transducer............................................303 Section 6 - Mast / Rotary Drive / Pipe Rack..................................304 Mast Weldment............................................................307 Mast Repair..........................................................307 Mast Assembly............................................................308 Mast Assembly........................................................308 Mast Pivot...........................................................309 Feed Cylinders...........................................................310 Feed Cylinder - Removal..............................................312 Feed Cylinder Assembly...............................................314 Repair...............................................................315 Installation.........................................................315 Hoist / Pulldown Cable Adjustment........................................316 Hosit / Pulldown Cable Adjustment....................................317 Hoist / Pulldown Cable Replacement...................................320 Rotary Drive Assembly....................................................321 Rotary Head Guide Alignment..........................................322 Rotary Head - Drive System...........................................323 Rotary Drive - Removal from Mast.....................................324 Rotary Drive - Installation..........................................324 Rotary Drive Gearbox.....................................................325 Rotary Drive Gearbox - Item Listing..................................326 Rotary Head Bull Shaft Bearing Nut...................................326 Rotary Drive Gearbox - Repair........................................327 Air Swivel...........................................................328 Winch Assembly...........................................................329 Precautions on the use of Winches....................................329 Wedge Socket.........................................................331 Grooved Drums........................................................332 Plain (Smooth) Drums.................................................332 Drums - Multiple Layers..............................................332 Winch Assembly Service...............................................333 BG8A and BG8B Hydraulic Winch Service Manual.........................334 Deck Wrench..............................................................365 H.O.B.O. Wrench..........................................................366 Breakout System - HOBO...............................................367 Hydraulic Operated Bit Basket - HOBB.................................367 Pipe Safety Arm......................................................367 Pipe Positioner..........................................................368 Carousel Pipe Rack.......................................................369 Major Components.....................................................369 Rod Handling - Carousel Indexing.....................................370 Carousel Pipe Rack Assembly..........................................371 General Information..................................................372 Pipe Rack Bearings - Removal.........................................372 Pipe Rack Componetns - Inspection....................................375 Pipe Rack - Assembly and Installation................................376 Pipe Rack Roller - Remove and Replace................................377 Pipe Rack Roller - Disassembly and Assembly..........................378 Section 7 - Hydraulic Systems................................................380 Hydraulic Symbols........................................................385 Pressure Setting Sequence................................................387 Pressure Setting Sequence............................................387 Hydraulic Tank...........................................................389 Hydraulic Tank.......................................................389 Return Hydraulic Filters.............................................390 Main Return and Case Drain Filters.......................................391 Routine Maintenance..................................................392 Changing Filter Elements.............................................392 Main Hydraulic Pumps.....................................................393 Pump Identification..................................................393 Right Track, Left Track / Rotation Pumps.................................394 Hydraulic Piston Pumps - Removal and REplacement.....................394 AA4VG 180 Hydraulic Pump HD/D Control................................395 Technical Data.......................................................397 Port Locations.......................................................401 Setting Procedure....................................................402 Charge Pressure, High Pressure, P.O.R. and Zero Position Settings....403 Set Charge Pressure - 450psi (31 bar)................................403 Set Crossover Relief (High Pressure) - 5500psi (380 bar).............404 Set Pressure Override (P.O.R) - 5000psi (345 bar)....................405 Set Mechanical Zero Position - HD Pump Control.......................406 Set Hydraulic Zero Position - HD Pump Control........................407 Removal and Inspection of Charge Pump................................408 Removal and Installation of Shaft Seal...............................409 Routine Maintenance..................................................410 Charge Circuit...........................................................413 Charge Filter............................................................415 Routine Maintenance..................................................415 Changing Filter Elements.............................................415 Main Pumps Circuit.......................................................417 Main Pumps Circuit...................................................417 Loop Filters.............................................................419 Routine Maintenance..................................................419 Changing Filter Elements.............................................422 Rotation Circuit.........................................................423 Rotation Circuit.....................................................423 Rotary Drive Gearbox Motor...............................................425 Rotary Drive Gearbox Motor - Test and Repair.........................425 Shaft Seal Replacement...............................................426 Trouvle Shooting.....................................................428 Tram Circuit.............................................................430 Tram Circuit.........................................................430 Feed and Auxiliary Pump Circuit..........................................432 Hydraulic Piston Pumps - Removal and Replacement.....................432 Feed and Auxiliary Functions Pump....................................435 Repair Instructions..................................................436 Pump Replacement - Start Up..........................................437 Hydraulic Systems........................................................439 Auxiliary and Feed Circuits..........................................439 Main Control Valves......................................................440 Valve Stand Assembly.................................................440 MP18 Valve - Jack and Mast Raise Valve...................................441 MP22 Valve - Hoist and Pulldown Control..................................443 4WE6 - Aux. Functions and Mast Valves....................................446 Repair Kits..........................................................448 Exploded View of 4WE6................................................449 Counterbalance Valves....................................................450 Counterbalance Valve Adjustment......................................450 Pilot Control Manifold...................................................451 Control Valve Assembly...................................................453 Auxiliary Pump Load Solenoid Valve...................................453 Hydraulic Feed Circuit...................................................459 Feed Valve Assembly......................................................464 Jack Control and Mast Elevating Circuit..................................467 Jack Control and Mast Elevating Circuit..............................468 Leveling Jack Cylinders..................................................469 Counterbalance Valve Test Procedure..................................470 Mast Elevating Cylinders.................................................471 Counterbalance Valve Test Procedure..................................472 Auxiliary Functions Circuit..............................................473 Auxiliary Functions Circuit..........................................473 Hydraulic Operated Breakout Wrench.......................................475 Setting of HOBO Sequence Valves......................................476 Cooler Fan Circuit.......................................................477 Fan Motor Circuit....................................................477 Cooler Fan Motor.........................................................480 Hydraulic Motor......................................................480 Hydraulic Thermostatic Valve.............................................484 Hydraulic Cooler - Thermal Valve.....................................484 Central Lube.............................................................485 Hydraulic Circuit....................................................486 Air Conditioner Compressor Drive Circuit.................................487 Air Conditioner Drive Motor..............................................488 Design...............................................................488 Operational Check....................................................488 Shaft Seal Replacement...............................................489 Screw Tightening Torque..............................................489 Gear Backlash........................................................489 Specifications.......................................................489 Parts List...........................................................490 Water Injection Circuit..................................................491 Water Injection Valve................................................492 Water Injection Valve....................................................494 Introduciton.........................................................494 Valve Stack Assembly.................................................495 Segment Alterations..................................................496 Pulsar Solenoid Removal and Plug.....................................498 Recommended Test Stand...............................................499 Final Stack Adjustment...............................................502 Assembly Drawing - VBL Bypass Inlet Segment Parts List...............508 Assembly Drawing - VPL Work Segment Parts List.......................510 Water Pump Motor.........................................................512 Water Pump Motor Repair Information..................................512 Shaft Seal Repair....................................................513 Hydraulic Cylinder Repair................................................516 General Information..................................................517 H Head...............................................................519 N Head...............................................................520 Z Head...............................................................521 Z Head ( Two Piece)..................................................522 K Head...............................................................523 M Head...............................................................524 Z Piston.............................................................525 Z Piston (Threaded)..................................................526 H & K Piston.........................................................527 M Piston.............................................................528 N Piston.............................................................531 Section 8 - Electrical Components............................................534 Electrical Locator.......................................................537 Electrical Locator Parts List........................................539 Jump Starting............................................................540 Batteries................................................................542 Welding Precautions......................................................543 Vigilante Guide..........................................................544 Important Information................................................544 PLC..................................................................545 EEPROM...............................................................546 Output Card..........................................................547 Touchscreen..........................................................548 Laser Depth System...................................................549 Safety Instructions & Precautions....................................550 Pipe in Hole Detection...............................................551 Distance Meter.......................................................551 Start Up and Shut Down...............................................552 Hydraulic Function Enable............................................552 Alarms...............................................................552 Solenoid Control.....................................................553 Auto Lube............................................................556 Hammer Oiler System..................................................556 Gauges...............................................................557 Pressure Transducer..................................................557 Level Transducer.....................................................557 Hammer Oil Level Transducer..........................................557 Temperature Transducer...............................................558 Water Flow Transducer................................................560 Inclinometers........................................................561 Head Speed Module....................................................562 Level Switches.......................................................563 Dust Suppression.....................................................563 Turkey Spray.........................................................563 Water Suppression Tank - Top Up......................................563 Vigilante System Component Information...................................564 Head Speed Module....................................................564 Inclinometer.........................................................566 Ladder Prox Switch...................................................569 LDM 40 A Laser.......................................................570 Level Switches - Capacitive Level Switch (Hydraulic Oil Level).......582 Radiator Level Switch................................................586 Level Transducer - Electronic Level Sensor...........................590 Hammer Oil Level Transducer..........................................600 Pressure Transducer - Combined Pressure Sensor.......................602 Temperature Transducer - Control Monitor for Temperature Sensors.....611 Section 9 - Lubrication and Preventive Maintenance...........................648 Central Lube System......................................................651 Hydraulic Control Schematic..........................................652 Auto Lube............................................................652 Central Lube Pump Module.............................................656 Central Lube Pump....................................................669 Bit Oiler Tank Assembly..................................................695 Bit Oil Circuit..........................................................696 Bit Oil System...........................................................697 Air Service Unit Components..........................................697 Filter Regulator.....................................................698 Air Line Oiler.......................................................699 Fire Ball 425 Pump - Instructions....................................700 Pipe Thread Lubricator...................................................717 Air Service Unit.....................................................717 Filter Regulator.....................................................718 Air Line Lubricator..................................................719 Pipe Thread Pump.....................................................720 Filter Locator...........................................................728 Lubrication General......................................................730 Equipment Lubrication................................................730 Care of Lubrication Points...........................................730 Lubrication and Preventive Maintenance...................................731 Safety...............................................................731 Track Gear...........................................................731 Engine Maintenance...................................................733 Air Cleaners.........................................................734 Air Filter Elements..................................................734 Alternator Maintenance...............................................734 Pump Drive and Drive Shaft Maintenance...............................735 Compressor Maintenance...............................................735 Cooler Packs.........................................................735 A-Frame and Pivot Point Maintenance..................................737 Pull Down and Hoist Ropes and Sheaves Maintenance....................737 Hydraulic System Maintenance.........................................739 Hydraulic Maintenance................................................739 Water Pump Maintenance...............................................739 Cab Maintenance......................................................739 Air Conditioner Maintenance..........................................741 Battery Maintenance..................................................741 Lubrication System Maintenance.......................................741 Fire Suppression Maintenance.........................................741 Lubrication and Maintenance Chart 250hr..................................743 Lubrication and Maintenance Chart 500hr..................................753 Lubrication and Maintenance Chart 1000hr.................................764 Lubricant Specifications.................................................773 Hydraulic System.....................................................773 Hydraulic Tank Capacity..............................................773 Compressor Lubrication...............................................774 Compressor Lubricant Specifications..................................774 Lubricating Grease...................................................775 Gear Lubricant.......................................................775 Scheduled Oil Sampling Analysis......................................775 Torque Valves for Split Flange Connections...............................776
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