Cat Bucyrus Series SKSS Infinity Blasthole Drill Service Manual SN 1N67Y54 – PDF DOWNLOAD

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Cat Bucyrus Series SKSS Infinity Blasthole Drill Service Manual SN 1N67Y54 – PDF DOWNLOAD

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Cat Bucyrus Series SKSS Infinity Blasthole Drill Service Manual SN 1N67Y54 – PDF DOWNLOAD

Language : English
Pages : 861
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Cat Bucyrus Series SKSS Infinity Blasthole Drill Service Manual SN 1N67Y54 – PDF DOWNLOAD

Safety:

• The Rotary Drill is a heavy moving machine with a mast which raises vertically for drilling. Like
  all moving objects and reach extending devices, there are potential hazards associated with its
  use. These hazards will be minimised if the machine is properly inspected and maintained. The
  maintainers must read this manual and have been trained to use the machine in an appropriate and
  safe manner. Should any questions arise concerning the maintenance or operation of the machine
  contact Reedrill in your state or territory.
• There are many personal hazards and dangers associated with working on and around a drill rig. If
  the safety instructions outlined in this section are adhered to, risk of injury or harm to yourself
  and others will be significantly reduced.

TABLE OF CONTENTS:

Cat Bucyrus Series SKSS Infinity Blasthole Drill Service Manual SN 1N67Y54 – PDF DOWNLOAD

Introduction
Parts Ordering & Product Support i
Safety Information ii
Product Description iii
Manual Contents iii
Table of Contents iv
General Locator xiv
Section 1
Safety 1-2
Safety locator 1-8
Section 2
Operator’s Controls and Indicators 2-2
Control Panels 2-2
Right Hand Control Panel 2-3
Circuit Breakers 2-4
Light Switches 2-5
Instrument Panel 2-5
Instrument Panel and Circuit Breakers 2-5
System Pressure Gauge Panel 2-6
Left Hand Control Panel 2-8
Air Conditioner 2-15
Introduction 2-19
Unit Specification 2-20
Technical Data and Control Settings 2-24
Installation and Commissioning 2-26
Operating Instructions 2-36
Routine Maintenance Procedures 2-39
Fault Diagnosis 2-47
Warranty 2-58
Basic Spare Parts Listing 2-59
Reference Drawings 2-62
Condenser 2-67
Evaporator 2-68
Compressor 2-71
Section 3
Main Frame Repair 3-2
Welding Manual 3-2
Leveling Jacks 3-38
Remove-Replace 3-39
Mast Elevating Cylinders 3-40
BI620442
SKSS Introduction v
Table of Contents
Remove-Replace 3-42
Crawler Assembly 3-44
Crawler Component Repair 3-45
Metric Bolt Torque Specifications 3-46
Track Maintenance 3-47
Before Operating the Machine: 3-47
General Maintenance 3-47
Track Tension Adjustment 3-48
Description 3-50
Nitrogen Tensioner 3-51
Hydraulic Tensioner 3-52
Nitrogen Tensioner Assemby 3-53
Nitrogen Tensioner – Filling Instructions 3-54
Nitrogen Tensioner – Pressure Check 3-56
Nitrogen Tensioner – Pressure Release 3-56
Track Chain – Separate 3-58
Track Chain Repair 3-60
Track Link – Repair and Replace 3-60
Track Link – Description 3-61
Track Shoes Installation 3-62
Track Link Position 3-62
Track Shoe – Mounting to Track Chain 3-62
Track Shoe Bolt Torque (Direct Torque Method) 3-64
Track Shoe Bolt Torque (Torque Turn Method) 3-65
Track Chain and Shoe Installation 3-66
Track Chain with Shoes 3-66
Track Chain & Shoe – Assembly & Installation 3-66
Final Drive 3-68
Final Drive – General Description 3-68
Final Drive Unit Removal 3-69
Removal from Track Frame 3-69
Installation into Track Frame 3-70
Final Drive Maitenance 3-71
Oil Check / Change 3-71
Final Drive Oil 3-72
Specifications 3-72
Recommended Oil 3-72
Final drive Assembly 3-74
Parking Brake – Description 3-75
Final Drive Disconnect 3-76
Final Drive – Disconnect & Parking Brake 3-77
Towing Procedure – Gear Drive Disconnect 3-77
Parking Brake – Removal & Installation 3-77
Idler Assembly 3-78
Idler Unit Removal 3-80
Idler Unit Assembly 3-82
Track and Support Rollers 3-86
BI620442
vi SKSS Introduction
Table of Contents
General Description 3-86
Track Roller – Removal & Disassembly 3-88
Support Roller – Removal & Disassembly 3-89
Track and Support Roller – Assembly 3-90
Track and Support Roller – Test and Install 3-91
Auxiliary Crane 3-93
Section 4
Power Group Locator 4-2
Engine 4-3
Engine Oil Reserve System 4-3
Engine Oil Reserve System Circuit 4-3
Wiring Diagram – Oil Reserve Basic Circuit 4-4
Oil Reserve Systems 4-5
LED Monitor Readings 4-6
Adjustment of Running Oil Level 4-6
Oil Reserves 4-7
Troubleshooting 4-7
Oil Reserves Systems – Maintenance 4-8
Engine and Air Cleaners 4-9
Engine and Compressor Air Cleaner Service 4-10
Flexible Drive Coupling 4-13
Flexible Drive Coupling Service 4-13
Removal 4-14
Installation 4-14
Pump Drive 4-16
Pump Drive Assembly – Removal and Replacement 4-16
Pump Identification 4-17
Pump Drive Gearbox 4-18
Pump Drive Gearbox – Repair 4-19
Disassembly: 4-19
Inspection and Repair: 4-19
Assembly: 4-19
Disassembly 4-21
Installation of Pump Drive Gearbox: 4-21
Lubrication: 4-21
Hydraulic Piston Pumps 4-22
Hydraulic Piston Pumps – Removal and Replacement 4-22
Tram and Rotation Pump 4-23
Application and Service Manual 4-23
Hydraulic Piston Pumps 4-52
Hydraulic Piston Pumps – Removal and Replacement 4-52
Feed and Auxiliary Pump 4-53
Repair Manual 4-53
Hydraulic Gear Pumps 4-84
Hydraulic Gear Pumps – Removal and Replacement 4-84
BI620442
SKSS Introduction vii
Table of Contents
Service Manual 4-85
Compressor Drive Coupling 4-98
Compressor Drive Coupling – Removal and Replacement 4-99
Compressor Installation 4-100
Compressed Air Functions 4-101
Before Installation: 4-101
Compressor Unit – Installation: 4-101
Before Start-Up of New or Rebuilt Compressor: 4-101
Main and Auxiliary Air 4-102
Functional Description 4-102
Compressed Air Subsystem Components 4-102
Compressor Circuit 4-103
Compressor Air End 4-104
Compressor Shaft Seal 4-105
Compressor Shaft Seal Replacement 4-105
Compressor Discharge Check Valve 4-108
Compressor Receiver Tank Assembly 4-109
Separator Elements 4-110
Separator Elements – Remove & Replace 4-112
Minimum Pressure Valve 4-113
Minimum Pressure/Check Valve Maintenance 4-113
Thermal By-pass valve 4-114
Thermal By-pass Valve Maintenance 4-115
Compressor Oil Filter 4-116
Routine Maintenance 4-118
Changing Filter Elements 4-118
Bearing Oil Filter 4-119
Bearing Oil Filter Element Replacement 4-119
Oil Stop Valve – 4-120
Oil Stop Valve Maintenance 4-121
Compressor Inlet Valve 4-122
Control System 4-122
Sullicon Control 4-122
Butterfly Inlet Valve 4-122
Compressor Inlet Valve Control 4-123
System Regulator 4-124
Relieving Regulators 4-124
System Pressure Regulator Maintenance 4-125
Blowdown Valves 4-126
Running Blowdown Valve 4-126
Running Blowdown Valve Maintenance 4-126
System Blowdown Valve 4-127
System Blowdown Valve Maintenance 4-127
Compressor discharge Temperature gauge and Senders 4-128
Compressor Oil Cooler Assembly 4-129
Radiator/Hydraulic Oil Cooler Assembly 4-130
Radiator/Oil Cooler Assembly 4-131
BI620442
viii SKSS Introduction
Table of Contents
Aluminium Tube Oil Coolers 4-132
Service Manual 4-132
Copper Tube Oil Coolers 4-140
Service Manual 4-140
Radiator and Core Assembly 4-148
Service Manual 4-148
Section 5
Dust Control Systems 5-2
Water Injection 5-3
Water Injection Control 5-5
Basic Water Injection System Circuit 5-7
Water Pump 5-8
Servicing Instructions 5-9
General Care of the Pump 5-9
Servicing the Plunger Packings 5-9
Reassembling Plunger Packings 5-11
Servicing the Pump Valves 5-12
Pump Specifications 5-14
Torque Requirements 5-14
Reassembling Valve Parts 5-14
Servicing the Crankshaft 5-14
Servicing the Crossheads 5-16
Recommended Lubricants 5-17
Water Pump Motor Repair 5-17
Water Pump Drive Coupling 5-17
Water Pump Motor 5-18
Service Manual 5-18
High Pressure Cleaner 5-26
Section 6
Mast Weldment 6-2
Mast Repair 6-2
Mast Assembly 6-3
Mast Pivot 6-4
Feed Cylinders 6-5
Feed Cylinder – Removal 6-8
Feed Cylinder Assembly 6-10
Installation 6-11
Hoist/Pulldown Cable Adjustment 6-12
Hoist/Pulldown Cable Replacement 6-15
Rotary Head Guide Alignment 6-18
Rotary Drive Assembly 6-20
Rotary Drive – Removal from Mast 6-20
BI620442
SKSS Introduction ix
Table of Contents
Rotary Drive – Installation 6-20
Rotary Drive Gearbox 6-21
Rotary Drive Gearbox – Repair 6-23
Main Shaft Bearing Preload 6-23
Winch Assembly 6-24
Precautions on the Use of Winches 6-24
Wire Rope 6-24
Winch Assembly Service Manual 6-31
Deck Wrench 6-60
HOBO Wrench 6-61
Breakout System – HOBO 6-62
Pipe Positioner 6-63
Carousel Pipe Rack 6-64
Major Components 6-64
Rod Handling-Carousel Indexing 6-65
Pipe Rack Bearings – Removal 6-67
Pipe Rack Components – Inspection 6-70
Pipe Rack – Assembly and Installation 6-71
Pipe Rack Roller – Remove and Replace 6-72
Pipe Rack Roller – Disassembly and Assembly 6-73
Section 7
Hydraulic Symbols 7-2
Pressure Setting Sequence 7-4
Hydraulic Tank 7-6
Main Return and Case Drain Filter 7-9
Routine Maintenance 7-10
Changing Filter Elements 7-10
Main Hydraulic Pumps 7-12
Pump Identification 7-12
Right Track Left Track/Rotation Pumps 7-13
AA4VG 180 Hydraulic Pump HD/D Control 7-14
Port Locations 7-16
Setting Procedure 7-17
Mechanical Zero Position – HD Pump Control 7-18
Hydraulic Zero Position – HD Pump Control 7-19
Charge Pressure, High Pressure and P O R Relief Settings 7-20
Set Charge Pressure 7-21
Set Crossover Relief 7-21
Set Pressure Override (P O R ) 7-23
Charge Filter 7-24
Routine Maintenance 7-25
Changing Filter Elements 7-25
Tram/Rotation Pump Circuit 7=27
Tram/Rotation Pump Circuit 7-28
Rotation Circuit 7-29
BI620442
x SKSS Introduction
Table of Contents
Rotation/Tram Motor Circuit 7-30
Loop Filters 7-31
Routine Maintenance 7-31
Changing Filter Elements 7-34
Rotary Drive Gearbox Motor 7-35
Rotary Drive Gearbox Motor – Repair 7-35
Case leakage By-pass test 7-35
Shaft Seal Replacement 7-35
Trouble Shooting 7-38
Feed and Auxiliary Pump 7-40
Feed & Auxiliary Functions Pump 7-41
Function of Load Sensing Control (DRS) 7-41
Adjustment Procedure 7-41
Auxiliary and Feed circuits 7-42
Main Control Valves 7-43
Valve Stand Assembly 7-43
MP18 Valve-Jack and Mast Raise Valve 7-44
MP22 Valve-Hoist and Pulldown Control 7-46
4WE6-Aux Function and Mast Valve 7-49
Counterbalance Valve 7-53
Counterbalance Valve Adjustments 7-53
Pilot Control Manifold 7-54
Control Valve Assembly 7-56
Individual Valves (V03 – V22) 7-56
Hydraulic Feed Circuit 7-64
Feed Valve Assembly 7-72
Jack Control and Mast Elevating Circuit 7-74
Pressure Adjustment 7-75
Leveling Jack Cylinders 7-76
Counterbalance Valve Test Procedure 7-77
Mast Elevating Cylinders 7-78
Counterbalance Valve Test Procedure 7-79
Auxiliary Functions Circuit 7-80
Hydraulic Operated Breakout Wrench 7-82
Setting of Sequence Valves 7-83
Cooler Fan Circuit 7-84
Fan Motor Circuit 7-84
Adjustment 7-84
Cooler Fan Motor 7-86
Basic Cooler Circuit 7-87
Cooler Fan Motor Assembly 7-88
Cooler Fan Motor Shaft Seal Change 7-89
Hydraulic Thermostatic Valve 7-92
Central Lube 7-93
Hydraulic Circuit 7-94
Air Conditioner Compressor Drive Circuit 7-95
Air Conditioner Drive Motor 7-96
BI620442
SKSS Introduction xi
Shaft Seal Replacement 7-98
Water Injection Circuit 7-100
Water Injection Valve 7-101
Toc-2 Controller 7-102
Water Injection Valve 7-103
Service Manual 7-103
Hydraulic Cylinder Repair 7-120
Hydraulic Cylinders Type Chart 7-120
Hydraulic Cylinder Overhaul Information 7-121
Section 8
Electrical Locator 8-2
Jump Starting 8-6
Precautions 8-7
Procedure: 8-7
Batteries 8-8
Welding Precautions 8-9
Vigilante Guide 8-10
Vigilante Guide Contents 8-10
Electrical Vendor Information 8-29
Head Speed Module 8-29
Inclinometer 8-31
Ladder Proximity Switch 8-35
Laser 8-36
Level Switches 8-38
Level Transducers 8-43
Pressure Transducers 8-54
Temperature Transducer 8-64
Water Flow Transducer 8-74
Water Control Module 8-89
Rod Counter Proximity Switch 8-98
Remote Fuel Level Display 8-99
Section 9
Central Lube System 9-2
Hydraulic Control Schematic 9-3
Central Lube System Circuit Drawing 9-5
Central Lube and Bit Lube Tank Assembly 9-6
Central Lube System 9-9
Central Lube Pump Module 9-9
Central Lube Pump 9-27
Vent Valve 9-50
SL-1 Injector Assembly 9-52
Central Lube and Bit Lube Tank Assembly 9-54
Bit Lube Circuit 9-56
Table of Contents
BI620442
xii SKSS Introduction
Bit Lube System 9-57
Air Service Unit Components 9-57
Filter Regulator 9-58
Air Line Oiler 9-59
Bit Lube Pump 9-60
Pipe Thread Lubricator 9-63
Air Service Unit 9-63
Filter Regulator 9-64
Air Line Lubricator 9-65
Pipe Thread Lubricator Pump 9-66
Filter Locator 9-74
Lubrication And Maintenance 9-76
Safety 9-76
Track Gear 9-76
Engine Maintenance 9-77
Air Cleaners 9-78
Air Filter Elements 9-78
Alternator Maintenance 9-78
Pump Drive and Drive Shaft Maintenance 9-79
Compressor Maintenance 9-79
Cooler Packs 9-80
A-Frame And Pivot Point Maintenance 9-80
Pull Down And Hoist Ropes And Sheaves Maintenance 9-81
Rotary Head Maintenance 9-81
Hydraulic System Maintenance 9-82
Hydraulic Maintenance 9-82
Bean Pump Maintenance 9-83
Cab Maintenance 9-83
Air Conditioner Maintenance 9-83
Battery Maintenance 9-84
Lubrication System Maintenance 9-84
Fire Suppression Maintenance 9-84
Lubrication – General 9-85
Equipment Lubrication 9-85
Care of Lubrication Points 9-85
Lubrication and Maintenance Chart – 250Hr 9-86
Lubrication and Maintenance Chart – 500Hr 9-96
Lubrication and Maintenance Chart – 1000Hr 9-107
Lubrication and Maintenance Chart – 2000Hr 9-118
Lubricant Specifications 9-131
Hydraulic System 9-131
Compressor Lubrication 9-132
Compressor Lubricant Specifications 9-132
Lubricating Grease 9-133
Gear Lubricant 9-133
Scheduled Oil Sampling Analysis 9-133
Torque Values for Split Flange Connections 9-134
Table of Contents
BI620442
SKSS Introduction xiii
Torque Values for Hydraulic Tubes & Fittings 9-135
Torque Values for Standard Fasteners 9-136

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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